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In the present article, an attempt is made to develop aluminium foam indigenously. The experimental setup for the production of aluminium foam is designed and fabricated. Investigation are made into the use of dual foaming agents (i.e. TiH2 and CaCO3) along with SiC to develop suitable aluminium foams which can be utilized for various engineering products like load-bearing elements, crash resistance elements etc. The process is standardized to produce aluminium foam with specific density with minimum variability. This aluminium foam produced possesses a very low coefficient of friction. This work successfully characterized the frictional properties of the developed material. In order to define the Frictional properties of this material, a mathematical model which uniquely defines the frictional behavior of this modified Al-MMC foam has been developed.

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Electrical Discharge Machining (EDM) is one of the most popular non-conventional machining processes that are being used in many high precision manufacturing industries. To increase the EDM performance, a hybrid technique, namely, powder mixed electrical discharge machining (EDM) (PMEDM) is generally used for getting more precise requirements. In this study, an experimental investigation is carried out in order to explore the machining performance of the PMEDM process on Ti-6Al-4V alloy using copper (Cu) powder in the EDM oil dielectric. Taguchi’s L18 orthogonal array design has been utilized for design of experiments and the analysis of variance (ANOVA) has been performed with the help of Minitab-19 software. The optimal parametric setting of Cu powder mixed EDM has been found utilizing the Taguchi - Grey Relational Analysis (GRA) integrated approach and also validation of optimal parametric setting is done through experimentation. It is a novel approach for machining Ti-6Al-4V alloy by this PMEDM technique in which the surface quality has been improved significantly with the addition of suitable amount of Cu powder into the dielectric medium.