Exploring AZ31B magnesium alloy for innovative micro products by reverse-μEDM

Abstract

• Fabrication feasibility test for arrayed microprotrusions of AZ31B Mg alloy. • The arrayed microprotrusions are in elliptical and aerofoil cross-sections. • Exploring Reverse-µEDM integrated with Laser beam µ-machining for this purpose. • Analysing surface finish, migration of tool materials to workpiece and MRR. Fabrication of complex and filigree magnesium alloy 3D-medical implants is very difficult by conventional processes. The present work examines the feasibility of fabricating arrayed microstructures (protrusions) of magnesium AZ31B Mg alloy in unconventional profiles. For this, Reverse-µEDM integrated with laser beam micromachining (LBµM), as a new hybrid technology, is employed. A capacitance of 10 nF, a voltage of 110 V and a feed rate of 10 µm/min for Reverse-µEDM led to better machining responses in terms of materials removal rate, tool wear, and avg. surface roughness compared to other parametric settings. Considering the importance of the biocompatibility of materials, the surface integrity of the fabricated microstructures is also analyzed.