Removal of adhesive powders from additive-manufactured internal surface via electrochemical machining with flexible cathode

Post-processing of additively manufactured metallic alloys – A review

“…Sustainable manufacturing should conserve energy and material with waste prevention and environment protection as integral parts of production [210]. As demonstrated here, there are attempts to use less aggressive and harmful acids, e.g., by using more environmentally-friendly salt solvents [204]. They might not be as effective in reducing surface roughness, but there is a space to develop more sustainable solutions that are safer to handle, and which could still be effective if combined with proper process parameters.…”

“…EP can be further used to machine internal surfaces. A recent study by Zhao et al [204] was concerned with ECM of internal holes of PBF-LB/304 L stainless steel, where the electrolyte was a 10 wt% NaNO 3 salt solution. The material-removal mechanisms responsible for removing semi-sintered particles/powder from the internal surface of the hole are shown in Fig.…”

“…First, there is a need to investigate the complex relationship between the electrical process parameters and the chemical aspects of an electrolyte, as well as their individual and synergistic effects on the capability of EP to smooth and brighten AM surfaces. The majority of reported results are purely experimental, with some exceptions that attempted to model and simulate the current density distribution on the AM surface [204] or the evolution of material removal/surface smoothing [202]. Such efforts are needed to reduce the time-consuming experimental effort and/or dependency on commercial turnkey solutions.…”

Alternating chempolishing and electropolishing for interior and exterior surface finishing of additively manufactured (AM) metal components

“…al. focused on removal of powders from additive-manufactured internal surface via electrochemical machining by utilizing exible cathode [17]. Ye et al have conducted excellent study on the effects of different surface nishing methods, their work show that surface nishing methods can signi cantly impact fatigue like dynamic mechanical properties [18].In our prior work, we discussed the application of electropolishing mainly for improving the surface roughness of the exposed AM component surfaces [19][20][21].…”

Study on the Key Technology of Electrochemical Machining Flow Field in Aero-Rotor Blades

“…Along with the rapid development of aerospace industry in recent years, the light weight and high performance of the material under the action of gas working fluid through high distortion and thin-walled blade structure has gradually become the development goal of the new generation aeroengine [2][3], and the complex shaped structure products with this new special alloy material have the poor tool accessibility, serious tool loss and easy deformation of blade profile in NC milling technology [4]; and the thermal re-casting layer and the heat affected zone after EDM will interfere with the forming quality of the key parts of the blade surface [5]. While electrochemical machining (ECM), as a non-contact electrochemical etching technology, can solve the problems of traditional NC milling by virtue of its advantages of not limited by the properties of workpiece materials, no loss of tool cathode and high machining efficiency [6], and electrochemical machining uses high-speed electrolyte to replace EDM with high-temperature breakdown discharge melting by electrochemical etching, thus avoiding the influence of hot casting layer and heat affected zone on molding quality to obtain excellent surface [7]. However, for electrochemical machining, electrochemical etching of anode materials is completely based on the electrochemical characteristic distribution of the electrolyte in the machining gap, considering that the distribution of electrolyte electrochemical characteristics in the machining gap is determined by the electrolyte flow channel structure by controlling the fluid mass transfer process, and finally acting on the forming quality through the distribution of electrochemical etching characteristics in various parts of the machining surface, therefore, the rational design and optimization of the flow channel is of great significance in the process of ECM.…”