Material Removal Mechanism in Photocatalytic−Assisted Jet Electrochemical Machining of SiCp/Al

Abstract

Silicon carbide particle reinforced aluminum matrix (SiCp/Al) composites are increasingly used in high−end industries because of their superior comprehensive material properties. However, their advanced properties also create severe challenges for traditional processing technologies. A new hybrid machining method named photocatalytic−assisted jet electrochemical machining (PAJECM) is proposed to improve the machining capability by synchronously removing the metal aluminum matrix and the SiC particles. Comparative experiments were carried out on whether photocatalysis was added. The results show that after photocatalytic−assisted jet electrochemical machining, the height of SiC particles’ extrusion on the surface is significantly reduced. Compared with jet electrochemical machining (JECM) without photocatalysis at the same processing voltage, the surface roughness value is reduced, and the processing quality is improved. In PAJECM, the aluminum matrix is removed by electrochemical anodic dissolution, while the SiC particles generate a SiO2 reaction layer through photocatalysis, and the TiO2 abrasive flow’s mechanical action repeatedly removes the reaction layer. The electrochemical polarization curves and energy diffraction spectroscopy elemental analysis confirmed the material removal mechanism of PAJECM. Based on analyzing the phenomenon of material removal in detail, a qualitative model of the PAJECM material removal mechanism is established. This study provides valuable insights into the material removal mechanism in photocatalytic and jet electrochemical machining composite processes.

A Review on Recent Achievements and Challenges in Electrochemical Machining of Tungsten Carbide

“…Feng et al (2022) investigate the potential of profound importance for low-valence tungsten reduction to prevent disproportionation reactions in molten alkali chlorides. Wang et al (2022) suggest a novel hybrid machining technique called photocatalytic-assisted jet electrochemical machining to enhance machining capacity by simultaneously removing the metal aluminium matrix and the SiC particles. Aseerullah et al (2022) use ANSYS software to analyse the CNC machining procedure of AA6082-T6.…”

“…As a result, electrolyte adjustments are required. Rataj et al concentrated on the WC6Co ECM (Wang et al, 2022). WC6Co specimens were processed through grinding by SiC leaf of various polishing degrees to a shiny surface through a diamond postponement.…”

Effects of Circular Hydraulic Jump on the Material Removal Characteristics of Jet Electrochemical Machining

“…Jet electrochemical machining (Jet-ECM) is a potential precision machining method, like other common electrochemical machining (ECM) processes such as electrochemical drilling 1 (ECD) and electrochemical machining with electrolyte suction tool, 2 it has no metal hardness limitations, no tool wear or thermal effect, and high surface quality after machining. In addition, it has high flexibility and process stability, which makes it widely used in surface finishing and complex structural machining of hard-to-cut metals, 3 such as the GH4169 alloy used in aero engine turbine blades, 4 the tungsten carbide alloys used in jet engines, 5 the WC6Co-type cemented carbide cutting tools, 6 the silicon carbide particle reinforced aluminum matrix (SiC p /Al) composites, 7 and the ultra-smooth copper surfaces used in integrated circuits. 8 The circular hydraulic jump (CHJ) is the key factor in ensuring the removal profile's stability and the removal range's localizability in Jet-ECM.…”