Eco-friendly EDM electrode development using copper-coated recycled aluminium chips

Abstract The recycling of aluminium chips as feedstock for new functional components contributes significantly to sustainable manufacturing while reducing landfill waste and raw material dependency. Nowadays, there is a rising need for cheaper, eco-friendly tool materials, especially for EDM. This study explores development of an eco-friendly EDM electrode fabricated from recycled AA6061 machining chips consolidated via hot extrusion and enhanced through copper electroplating. Extrusion temperatures of 450 °C, 500 °C and 550 °C were evaluated, followed by copper coating to investigate electrical resistance and coating thickness. The 550°C extruded sample showed the lowest electrical resistance (best results), with 14.55 mΩ resistance and a 4.62 µm coating. A full-factorial design of experiments (2 4 with centre points) was applied to optimise CuSO 4 concentration, pH, current and electroplating time (ET) effects. Statistical analysis confirmed the optimal coating achieved at 300 g CuSO 4 , pH 3, 1000 mA and 3 h (ET), resulted in 8.55 mΩ resistance. In summary, these findings can support sustainable manufacturing, reduce CO 2 emissions, and promote a circular economy worldwide.