nontraditional manufacturing - limitations

USM

Low MRR compared to other processes

Not ideal for soft/ductile metals

Abrasive slurry handling required

WJC

Not suitable for brittle materials (glass fractures)

Not effective on metals alone — needs abrasives (see AWJC)

Cannot cut thick metals effectively

AWJC

Abrasive cost and waste disposal

Wider kerf than pure WJC

Cannot cut very thick sections with high precision

AJM

Usually a finishing process, not primary cutting

Low MRR

Usually manually directed by operator

ECM

Workpiece must be electrically conductive

Electrolyte disposal is an environmental concern

Tool must be designed as inverse of desired shape

ECD

Limited to deburring application only

Conductive materials only

ECG

Conductive only

EDM

Conductive materials only

Recast layer created on surface

Heat affected zone

Slow MRR compared to conventional

MRR decreases as Tm of work increases

Wire EDM

Only 2D profiles (extrusion of a path)

Conductive materials only

Wire must be continuously replaced

EBM

MUST operate in vacuum — electrons scatter off air molecules

Best suited for small parts (vacuum chamber limits size)

Hazardous X-rays produced — trained personnel required

Very expensive equipment

High energy consumption

LBM

Generally used on thin stock only

Heat affected zone on metals

No vacuum needed (unlike EBM)

PAC

Electrically conductive materials only

Large heat affected zone

Not precision process — significant HAZ and kerf width

OFC

Only ferrous/mild steel — NOT aluminum, stainless (they form protective oxides)

Aluminum and SS oxides have higher Tm than base metal — reaction stops

Requires preheating time

CHM

Cannot produce sharp internal corners (undercutting occurs)

Slow for deep cuts

Chemical waste disposal concerns