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Advances in Electrochemical Machining of Hard-to-Machine Materials
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Advances in Electrochemical Machining of Hard-to-Machine Materials

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 January 2025 | Viewed by 3379

Special Issue Editors

Prof. Dr. Hansong Li

E-Mail Website
Guest Editor
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: Electrochemical machining; hard-to-machine materials; electrochemical characteristics; electrochemical reaction mechanism.
Dr. Xiaolei Chen

E-Mail Website
Guest Editor
State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou 510006, China
Interests: electrochemical machining; hard-to-machine materials; electrochemical characteristics; electrochemical reaction mechanism

Special Issue Information

Dear Colleagues,

Electrochemical processing is not limited by the physical properties of materials. It can be used in a wide range of characteristic structural processing tasks involving challenging materials, such as those used in aerospace, aviation, and national defense fields.

This Special Issue will collect papers exploring advanced electrochemical machining methods for hard-to-machine materials. Experimental works that demonstrate an apparent improvement in processing efficiency or processing quality are of particular interest. Theoretical analysis of experimental results will also be considered. Corrosion protection and electrodeposition are the most important aspects related to the function of metallic components; the corrosion behavior, mechanism and electrodeposition process of various materials are also highlighted for this Special Issue.

Materials of interest include various composite metals and metal-based reinforced phase materials that are costly and inefficient to machine using conventional methods, or materials that have significant machining needs in the aerospace field.

Full papers, communications, and reviews are all welcome. We look forward to receiving your contributions.

Prof. Dr. Hansong Li
Dr. Xiaolei Chen
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • electrochemical machining
  • hard-to-machine materials
  • composites
  • corrosion
  • materials characterization
  • electrodeposition
  • electrochemical additive manufacturing
  • processing quality amelioration
  • theoretical and experimental approach

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Published Papers (3 papers)

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Editorial

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3 pages, 146 KiB  
Editorial
Editorial: Recent Research of Complex Structure Machining Technology for Hard-to-Machine Materials
by Shukai Fan, Xiaoyun Hu and Hansong Li
Materials 2024, 17(2), 340; https://doi.org/10.3390/ma17020340 - 10 Jan 2024
Viewed by 874
Abstract
With the development of machining technology, the application scenarios of national defense and military equipment, civil aviation vehicles, and reciprocating air and space vehicles are becoming more and more complicated [...] Full article
(This article belongs to the Special Issue Advances in Electrochemical Machining of Hard-to-Machine Materials)

Research

Jump to: Editorial

17 pages, 5649 KiB  
Article
Machining Surface Improvement through Electric- and Flow-Field Adjustments in Flying Electrochemical Milling of AA 2219
by Shukai Fan, Xiaoyun Hu, Junzhi Shen, Xin Ma and Hansong Li
Materials 2024, 17(4), 829; https://doi.org/10.3390/ma17040829 - 8 Feb 2024
Cited by 1 | Viewed by 863
Abstract
Electrochemical milling is an ideal technique for machining large-scale 3D structures that consist of aerospace aluminum alloys. The distribution of the electric and flow fields are vital to the quality of the machined surface, and the structures of the inner flow channel and [...] Read more.
Electrochemical milling is an ideal technique for machining large-scale 3D structures that consist of aerospace aluminum alloys. The distribution of the electric and flow fields are vital to the quality of the machined surface, and the structures of the inner flow channel and bottom outlet have different effects on the electric and flow fields on the machining surface. In this study, two specialized structures of a tool cathode were optimized by simulating the electric and flow fields, and a reasonable design basis for the tool cathode was obtained. Based on this, an ECM experiment was performed with the same machining parameters using different tools, and a 20 mm × 20 mm plane was machined. The experimental results showed that using an appropriate tool cathode can create ideal flow and electric fields, resulting in better processing. After optimizing, the machining plane arithmetic mean deviation decreased by 43% (from 14.050 μm to 6.045 μm), and the region elevation difference decreased by 52% (from 105.93 μm to 55.17 μm). Full article
(This article belongs to the Special Issue Advances in Electrochemical Machining of Hard-to-Machine Materials)
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16 pages, 11953 KiB  
Article
Analyzing the Relationship between the Chemical Composition and the Surface Finish of Alnico Alloys in EDM
by Piotr Młynarczyk, Damian Bańkowski and Bartłomiej Szwed
Materials 2023, 16(20), 6765; https://doi.org/10.3390/ma16206765 - 19 Oct 2023
Cited by 1 | Viewed by 1023
Abstract
The purpose of this study was to determine whether the chemical compositions of Alnico alloys had any effects on the electrical discharge machining (EDM) performance and the surface finish. This article compares the behavior of three different Alnico alloys in electrical discharge machining. [...] Read more.
The purpose of this study was to determine whether the chemical compositions of Alnico alloys had any effects on the electrical discharge machining (EDM) performance and the surface finish. This article compares the behavior of three different Alnico alloys in electrical discharge machining. The experiments were conducted under different conditions using a BP93L EDM machine (ZAP BP, Końskie, Poland), applying an additional rotary motion to the electrode. A Box–Behnken experimental design was employed to analyze the influence of three factors, i.e., the spark current, the pulse-on time, and the pulse-off time, at three levels for three Alnico alloys. The material removal rate (MRR) was calculated for the different process parameters. After the EDM, the surface roughness was studied using a Talysurf CCI Lite non-contact profiler (Taylor–Hobson, Leicester, UK). The next step of the experiments involved preparing metallographic specimens to be observed by means of scanning electron microscopy (SEM) and optical microscopy (OM). Measurements of the nanohardness were also performed. The experimental data were then analyzed using Statistica software version 10 (64-bit) to determine and graphically represent the relationships between the input and output parameters for the three Alnico alloys. The chemical compositions of the Alnico alloys affected the thickness of the white layer (higher cobalt content, lower white layer thickness) and the material removal rate. The higher the cobalt content, the thinner the white layer and the lower the material removal efficiency. Moreover, the cobalt content in Alnico alloys influenced the shape of the precipitates; these ranged from spheroidal (13% Co) to mix-shaped (21.3% Co) to flake-shaped (32.2%). The hardness of the resulting white layer was 874 HV at10 mN. Full article
(This article belongs to the Special Issue Advances in Electrochemical Machining of Hard-to-Machine Materials)
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