The aim of the study is to predict the surface topological characteristics of Al-B4C composite electrodes and the OHNS Die steel in the Electrical Discharge Machining (EDM) Process. The surface characteristics of Composite electrodes are evaluated by using Scanning Electron Microscopy (SEM) and EDAX Analytical Method. Surface roughness and hardness of the OHNS die steel was measured by the Stylus probe and Brinnel hardness. The composite electrodes prepared by the Aluminium 6063 and B4C materials. Both elements are mixed at molten state in the stir casting process at different compositions. The chemical composition properties of the Composite electrode is analyzed by the SEM and EDAX testing. The surface Roughness of the OHNS steel measured by the Brinell hardness tester. Based on the SEM and EDAX results, the 92% Al 8% B4C was producing the good surface roughness in OHNS die steel.

In spray deposition, a stream of molten metal is atomised with an inert gas to form a spray of molten droplets; these are then accelerated towards a substrate where they impinge and consolidate. Near-net shape products can be manufactured by technologies involving solidification and droplet consolidation. In order to maximise the metallurgical benefits of gas atomisation and deposition, a thorough characterisation of momentum and heat transfer is required in the gas atomised spray.This paper describes a mathematical model to predict thermal history and solidification behaviour of atomised droplets of aluminium, copper and nickel during flight. The model estimates nucleation temperature, nucleation position and the extent of droplet solidification during flight. The influence of the type of metal, atomising gas, deposition distance, different gas velocity correlations and droplet size on solidification characteristics are discussed.