“…Therefore, craters are formed on both electrodes with each spark-namely, a large one formed on the workpiece and a smaller one on the wire electrode. Besides the surface defects such as cracks, gas voids, plastic deformation, and the buildup of residual stress caused by the rapid cooling rate at the end of discharging, [4][5][6][7] a recast layer is always formed on the electrical-discharged surface, which is composed of several microscopic metallurgical layers, dependent on the machining conditions, electrode materials, and discharge mechanisms. [4,6,8,9] Although WEDM has been used for many decades, few works have studied the microstructure of the recast and *PHILIPS is a trademark of Philips Electronic Instruments Corp., Mahwah, NJ.…”