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Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for various responsible applications allowing products to work under extreme mechanical and thermal loads (up to 1000 °C). The problem of high-precision forming complex-shaped parts is a known engineering challenge due to the insulating properties of aluminum-containing ceramics and the formation of chemically active carbides in a hydrocarbon medium. The alternative approach for electrical discharge machining non-conductive sintered Al2O3 in the water-based medium using nickel-chrome plasma-vapor-deposed coating of 12 mm, SnO powder suspension (particle diameter of ⌀10 µm, concentration of 150 g/L), and brass wire-tool is proposed. The productivity was evaluated by calculating the material removal rate and discharge gap for various combinations of pulse frequency and duration. The maximal material removal rate of 0.0014 mm3/s was achieved for a pulse frequency of 30 kHz and pulse duration of 1.7–2.5 μs. The recommended value of the interelectrode gap is 48.0 ± 4.9 µm. The possibility of electrical discharge machining aluminum-containing insulating ceramics without using hydrocarbons, carbon and copper-group assisting measures was proposed and shown for the first time. The chemical content of the debris in the interelectrode gap between components of the materials was thermochemically analyzed.
Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for various responsible applications allowing products to work under extreme mechanical and thermal loads (up to 1000 °C). The problem of high-precision forming complex-shaped parts is a known engineering challenge due to the insulating properties of aluminum-containing ceramics and the formation of chemically active carbides in a hydrocarbon medium. The alternative approach for electrical discharge machining non-conductive sintered Al2O3 in the water-based medium using nickel-chrome plasma-vapor-deposed coating of 12 mm, SnO powder suspension (particle diameter of ⌀10 µm, concentration of 150 g/L), and brass wire-tool is proposed. The productivity was evaluated by calculating the material removal rate and discharge gap for various combinations of pulse frequency and duration. The maximal material removal rate of 0.0014 mm3/s was achieved for a pulse frequency of 30 kHz and pulse duration of 1.7–2.5 μs. The recommended value of the interelectrode gap is 48.0 ± 4.9 µm. The possibility of electrical discharge machining aluminum-containing insulating ceramics without using hydrocarbons, carbon and copper-group assisting measures was proposed and shown for the first time. The chemical content of the debris in the interelectrode gap between components of the materials was thermochemically analyzed.
Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces contact loads and wear of cutting tools. However, most of the published works are related to the electrical discharge machining of alumina in hydrocarbons, which creates risks for the personnel and equipment due to the formation of chemically unstable dielectric carbides (methanide Al3C4 and acetylenide Al2(C2)3). An alternative approach for wire electrical discharge machining Al2O3 in the water-based dielectric medium using copper tape of 40 µm thickness and TiO2 powder suspension was proposed for the first time. The performance was evaluated by calculating the material removal rate for various combinations of pulse frequency and TiO2 powder concentration. The obtained kerf of 54.16 ± 0.05 µm in depth demonstrated an increasing efficiency of more than 1.5 times with the closest analogs for the workpiece thickness up to 5 mm in height. The comparison of the performance (0.0083–0.0084 mm3/s) with the closest analogs shows that the results may correlate with the electrical properties of the assisting materials.
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