Abstract
Titanium alloys have a wide range of applications in aerospace, however, this material is very sensitive to changes in the flow field during electrochemical machining (ECM) and suffers from frequent short-circuiting and poor surface quality. Studies have shown that optimization and improvement of the cathode structure often improve the processing properties of the material. To process titanium alloy under a steady state, the laser processing system was used to prepare cylindrical array microstructure on the end surface of cathode. The comparison between the original and improved cathode was conducted in ECM experiments. The experimental results showed that serious flow marks existed on the original cathode processing surface. Within the range of processable voltage, short circuits occurred at the processing heights of 1.823 mm and 1.655 mm. The improved cathode can process a bright finish surface without flow marks and there were no short circuits. The influence of two microstructure arrangements on the blade surface quality was also investigated. Compared to inline cylindrical array (ICA) cathode. The processing gap equilibrium flow rate of the staggered cylindrical array (SCA) cathode is about 0.3 L/min higher. The average surface roughness of the blade hub was reduced from 1.632 µm to 0.574 µm. Additionally, there are multiple layers of electrolysis products adhering to the non-machined surface and the machined sidewall of the blade. The oxygen content of the outer layer is higher than that of the inner layer, and the oxygen content of the non-machined surface is significantly higher than that of the machined sidewall. The microstructure cathode designed in this paper realizes the stable processing of titanium alloy in passivation electrolyte.
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