An Investigation in Sub-Millimeter Channel Fabrication by the Non-Aqueous Electrolyte Jet Machining of Zr-Based Bulk Metallic Glasses

Abstract

Zr-based bulk metallic glasses (BMGs) have many unique properties. Due to their excellent performance and manufacturing process, they have become a research focus in the material science community. Electrolyte Jet Machining (EJM) is a non-contact electrochemical processing method with high surface integrity and high material removal rate (MRR). In this research, the sub-millimeter channels fabricated by EJM on Zr-based BMGs have been studied to explore the dissolution mechanisms and surface integrity under different scanning rates and voltages. The results show that, with other machining parameters holding constant, an increase in voltage leads to a substantial enhancement in both the depth and width of the channels machined on Zr-based BMGs. Notably, the influence of voltage on the depth of the channels is particularly pronounced. Additionally, an escalation in scanning rate correlates with a decrease in channel depth, with minimal variation in channel width. This study indicates that alcohol-based EJM is an effective method to fabricate sub-millimeter channels and modulate structures on Zr-based BMGs.

Fabricating Precise and Smooth Microgroove Structures on Zr-Based Metallic Glass Using Jet-ECM

“…Cole et al [21] discovered that the corrosion products and the dense oxides generated in water-based electrolytes hindered the electrochemical machining (ECM) of Zr-based MG. To address this issue, they adopted a method of increasing the bias voltage to reduce the adhesion of corrosion products to the machined surface. Subsequently, Guo et al [22][23][24] proposed the utilization of non-aqueous-based methods for pulse electrochemical machining of microstructures on Zr-based bulk metallic glass. However, the machined microstructures exhibited uneven edges in the peripheral regions and pronounced flow marks on the bottom.…”