Kovar, nickel-cobalt-iron shape memory alloy (SMA) exhibits a unique combination of properties, including low thermal expansion, high electrical conductivity, and excellent resistance to corrosion which makes it a popular choice for a variety of applications, particularly in industries where precision and reliability are crucial. The novelty lies in the thorough examination of how different pulse durations, including on-time (Ton) and off-time (Toff), as well as wire tension (WT) and wire feed rate (WF), influence responses such as arithmetic mean roughness (Ra), material removal rate (MRR), cutting speed (CS), and kerf width (KW) during wire electrical discharge machining (WEDM). It was observed that Ton and WT were more significant than Toff and WF for most of the responses. The satisfactory level of error graph shows the efficiency of the overall experiments. This work provides valuable facts and information on the WEDM parameters for Kovar alloy, which will improve the manufacturing process's productivity, efficiency, and effectiveness.
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