Surface quality improvement using electro chemical machining process for γ-TiAl parts produced by electron beam melting

Demirtas, Hasan; Yilmaz, Oğuzhan; Subasi, Levent; Gunaydin, Aydemir; Bilgin, Güney Mert; Orhangul, Akin; Akbulut, Guray; Nesli, Safak

doi:10.1016/j.procir.2021.09.041

Cited by 10 publications

(2 citation statements)

References 15 publications

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“…Electrochemical machining (ECM) is a method of electrochemically dissolving and removing materials by a high-rate way from workpiece and widely employed in various industrial applications, particularly for manufacturing complex-structured components made from difficult-to-machine materials, for example TiAl alloys. [1,2] Ti-48Al-2Cr-2Nb alloy is a two-phase material consisting of Ti 3 Al and γ-TiAl phases, exhibiting complex electrochemical dissolution behavior in electrolyte solution. [3,4] Previous studies have investigated the dissolution mechanism from various perspectives, including composition analysis, dissolution morphology, elemental composition, surface roughness, [5,6] as well as nonlinear dynamics.…”

Section: Introductionmentioning

confidence: 99%

High‐Dissolution Mechanism of Ti–48Al–2Cr–2Nb Alloy in Electrochemical Machining from a Nonlinear Dynamic Perspective

Lin,

Li,

et al. 2024

Adv Eng Mater

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The high‐rate dissolution process of Ti‐48Al‐2Cr‐2Nb alloy in electrochemical machining exhibits strong nonlinear dynamic characteristics, but the quantitative relationship between these nonlinear characteristics and surface topography, as well as the electro‐dissolution mechanism, is unknown. Therefore, the fractal and recursive features of dissolution behavior was investigated, and the dissolved surface topography was quantitatively characterized. Additionally, an electro‐dissolution mechanism model in electrochemical machining process was presented. Applying a moderate extraction potential of 8 V instead of 11 V can enhance the stability of the electrochemical system, resulting in a smoother and uniform surface. At 11 V, the saturation correlation dimension, surface roughness, and integral area of lacunarity initially decrease before increasing with higher electrolytic pressure, while laminarity (𝐿𝐴𝑀) and determinism (𝐷𝐸𝑇) show an initial increase followed by a decrease. These five characteristic parameters reach their optimal values at an electrolyte pressure of 0.4 MPa, indicating that achieving a stable and deterministic electrochemical system is crucial for obtaining a uniform smooth surface. These nonlinear dynamic characteristic parameters can be considered as in‐situ monitoring parameters for surface quality in ECM. The anodic dissolution process comprises three stages: initial passive film dissolution and breakdown, rapid dissolving with surface coarsening, and stable dissolving with polishing.This article is protected by copyright. All rights reserved.

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Section: Introductionmentioning

confidence: 99%

High‐Dissolution Mechanism of Ti–48Al–2Cr–2Nb Alloy in Electrochemical Machining from a Nonlinear Dynamic Perspective

Lin,

Li,

et al. 2024

Adv Eng Mater

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“…For electrical discharge machining and laser machining, recasting layers, micro-cracks or residual stresses are usually formed on the surface of samples, which have serious adverse effects on the serve life of parts [7,8]. Electron beam melting and addictive manufacturing usually result in very rough surface and poor pro le accuracy [9,10]. ECM is a very economical and promising manufacturing method for γ-TiAl alloy, which can overcome the above shortcomings.…”

Section: Introductionmentioning

confidence: 99%

Investigation on electrochemical characteristics of forged Ti-48Al-2Cr-2Nb in NaNO3 solution for its application on the manufacture of aero-engine blades

Wang

2023

Int J Adv Manuf Technol

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Electrochemical machining (ECM) has great advantages for the manufacture of di cult-to-cut γ-TiAl alloys considering its many inherent advantages over traditional cutting techniques. In this study, the ECM characteristics of a new forged Ti-48Al-2Cr-2Nb (TiAl 4822) intermetallic with α and γ phases were investigated in NaNO 3 solution. The polarization characteristics of the sample were studied by potentiodynamic and potentiostatic polarization tests. The results show that the alloy has typical active, passive, and transpassive regions, and the compactness and corrosion resistance of passive lm are getting better and better with the increase of test time at passive potential. The XPS test revealed that the main components of the passive lm are titanium dioxide and aluminum oxide. Furthermore, the alloy exhibits high material removal rates that remain almost constant in the range of current density less than 50 A/cm 2 . Moreover, the dissolution mechanism of TiAl 4822 alloy was also revealed through the dissolution morphology, elemental composition, surface roughness, and intergranular corrosion at different current densities. The sample shows a loose lamellar dissolution morphology and is very rough at low current density. The sample exhibits a very at surface at high current density, but many microbulges with high content of Cr element on the dissolved surface. Finally, several forged TiAl 4822 alloy blades were successfully fabricated with an average surface roughness of Ra 0.55µm. It is prove that ECM can obtain high surface quality and high material removal rate of forged TiAl 4822 alloy for complex structural components in aero-engines.

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Electrochemical machining of additively manufactured γ-TiAl parts: post-processing technique to reduce surface roughness

Demirtas

Cebi

Aslan

et al. 2023

Int J Adv Manuf Technol

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Surface quality improvement using electro chemical machining process for γ-TiAl parts produced by electron beam melting

Cited by 10 publications

References 15 publications

High‐Dissolution Mechanism of Ti–48Al–2Cr–2Nb Alloy in Electrochemical Machining from a Nonlinear Dynamic Perspective

High‐Dissolution Mechanism of Ti–48Al–2Cr–2Nb Alloy in Electrochemical Machining from a Nonlinear Dynamic Perspective

Investigation on electrochemical characteristics of forged Ti-48Al-2Cr-2Nb in NaNO3 solution for its application on the manufacture of aero-engine blades

Electrochemical machining of additively manufactured γ-TiAl parts: post-processing technique to reduce surface roughness

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