Bauxite residue (BR) is the hazardous waste produced during extraction of alumina by processing of bauxite ore. BR has an adverse effect on humans and the environment due to its disposable problem. To minimize the environmental impact, BR must be effectively utilized. One such way is to use BR as a reinforcing for metal matrix composite. In this study, Taguchi’s mixed fractional factorial experimentation (L18) approach is employed in the development of Al6063/BR composite through advanced stir casting process. The processparameters considered are stirring speed (rpm), reinforcement particle size (lm), reinforcement weight fraction (wt%) by weight of the matrix phase, pouring temperature (°C), and preheat temperature (°C). Later, ANOVA results indicate that particle percentage (wt%) is the major contributor in the development of porosity content. Moreover, the interaction of process parameters was also found to have an impact on porosity content. The outcome of the study reveals that the stirring intensity at 350 rpm, particle size at 80 lm, particle percentage at 2 wt%, pouring temperature at 730 °C, and preheat reinforcement temperature at 450 °C are the optimal conditions for fabricating defect free Al6063/BR composite

Inconel 706 is a nickel–iron-based superalloy having higher mechanical strength along with easiness of fabrication, which makes it suitable for gas turbine disk applications. The current study investigates the hybrid magnetic-field-assisted powder mixed electric discharge machining (MFAPMEDM) process to improveperformance in machining Inconel 706. For conducting experiments, an in-house set-up was designed and fabricated. Experiments were conducted according to the Taguchi L9 OA and ANOVA to examine the effect of the peak current (I_p) and pulse duration (P-on/P-off) on the material removal rate (MRR) and surface roughness (R_a) of the machined samples. The quality of the machined surface is assessed using a field emission scanning electron microscope (FESEM), which has revealed the presence of micro-holes, melted debris and microglobuleson the machined specimen surface. The R_a is significantly affected by I_p (49.63%) and P-off (37.12%).Further, I_p has more than 78% contribution to the MRR. Furthermore, a mathematical model has been established to develop the relation between input and output factors