Multi-physical analysis of the electrochemical behaviour of OFHC copper surfaces obtained by orthogonal cutting

Abstract

ABSTRACT As mechanical, physical and microstructural properties of metals can be significantly affected by the machining process, electrochemical properties and corrosion resistance are consequently altered. Manufacturers should control the impact of cutting conditions on surface integrity, as it will affect the component’s functional performance and life. This study addresses the case of orthogonal cutting of oxygen-free high conductivity copper. A set of experiments was performed and a statistical analysis was conducted to reveal the relationship between the cutting conditions and the surface integrity in terms of residual stresses, microstructure, plastic deformation and hardness and the impact of those parameters on the electrochemical behaviour. The physical origins of the observed phenomena are explained. The results show that the surface performance can be controlled by selecting the appropriate cutting conditions (e.g. reducing the tensile residual stress and roughness by more than 75%), such that the electrochemical behaviour can be enhanced. Highlights Performing orthogonal cutting tests varying cutting conditions on oxygen-free high conductivity (OFHC) copper. Analyzing mechanical and microstructural state of OFHC copper machined surfaces including roughness, residual stresses, grain size and dislocation density. Analyzing the electrochemical behaviour of the machined surfaces using polarisation curves issued from electrochemical microcell tests. Relating surface integrity mechanical and microstructural properties to electrochemical properties using statistical analysis. Optimising cutting conditions to control the surface integrity state and then ameliorate the corrosion resistance.