Process parameters and levels.

LM5 alloy is suitable for metal castings for marine and aesthetic uses due to its admirable resistance to corrosion. In order to make intricate shapes in the LM5 alloy, this study intends to assess the impact of Wire Electric Discharge Machining process variables, like Pulse on Time (Ton), Pulse off Time (Toff), Gap Voltage (GV) and Wire Feed (WF) on responses like Material Removal Rate (MRR), Surface Roughness (SR), and Kerf Width (Kw). The LM5 aluminium alloy plate was produced through stir casting process. SEM, EDAX and XRD images confirm the LM5 Al alloy’s microstructure and crystal structure. WEDM studies were conducted using design of experiments approach based on L9 orthogonal array and analysed using Taguchi’s Signal to Noise Ratio (S/N) analysis. Pulse on Time has the greatest statistical effects on MRR (68.25%), SR (79.46%) and kerf (81.97%). In order to assess the surface integrity of the WEDM machined surfaces, the SEM study on the topography was conducted using the optimum surface roughness process variables: Ton 110 μs, Toff 50 μs, GV 40 V, and WF 9 m/min. SEM images show the recast layer and its thickness. The average absolute error for MRR is 1.69%, SR is 3.89% and kerf is 0.88%, based on mathematical (linear regression) models. The Taguchi’s Signal to Noise ratio analysis is the most appropriate for single objective optimization of responses.