In the present research, composite electrode (Cu-Mn) manufactured through powder metallurgy has been used to machine hot die steel (H11) by Electrical Discharge Machining (EDM) process with the aim of inducing manganese and carbon into the machined surface. Such alloying is expected to improve the microhardness and other surface characteristics. Best level of process parameters for better surface finish and high microhardness are found using Taguchi method. Six processing parameters are considered and their significance is investigated by analysis of variance (ANOVA).Techniques like SEM, EDS and XRD are used to ascertain the surface characteristics.Surface machined at optimum process conditions for microhardness shows 93.7% improvement due to formation of cementite, ferrite and manganese carbide phases.Surface roughness having Ra value of 3.11 µm has been achieved.
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