Cobalt removal process from PDC with ultrasonication in neutral electrolyte

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Cobalt removal is considered a common method to improve the performance of polycrystalline diamond compact (PDC). To effectively reduce the pollution during the process of cobalt removal, a neutral electrolyte was used in this work to remove cobalt from PDC by electrolysis with ultrasonication. The electrode process and mass transfer model of cobalt removal in a NaCl–KCl solution were established by performing electrochemical impedance spectroscopy (EIS) measurements. Different electrode potentials and electrolytic durations were set to investigate the limits of cobalt removal in the neutral electrolyte. Cobalt removal was assessed by conducting potentiodynamic polarisation, scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) measurements. The ImageJ2x image analysis software was used to study the collected spectra. The experimental results indicated that cobalt was successfully removed in the neutral electrolyte and that ultrasonication enhanced its removal. The optimal electrode potential for cobalt removal in the NaCl–KCl solution was less than 500 mV or more than 2000 mV. As the electrolysis time increased, the porosity of the PDC surface first increased to 9.4 % and then decreased to 7.2 %, and the depth of cobalt removal was up to 224 μm. Over time, the rate of cobalt removal decreased, suggesting that the efficacy of ultrasonication in promoting the cobalt removal process gradually weakened as electrolysis products continued to accumulate.