Recast Layer Research Articles

Experimental investigation during nano powder added µ-ED milling on nickel-titanium shape memory alloy

Nickel-titanium (NiTi) shape memory alloy (SMA) is one of the smart materials which has a vast application in the aerospace and biomedical industry due to its shape memory effect (SME), strong corrosion and wear resistance. Thus, the present study investigates the influence of process variables like gap voltage (V), powder concentration (PC) and pulse on time (ton) towards the material removal rate (MRR), surface roughness (SR) and micro-hardness (MH) amid graphene nano powder added micro-electrical discharge milling (µ-ED milling) of NiTi SMA. ANOVA analysis has been carried out to determine the % distribution of individual machining parameters towards all responses. The addition of graphene nano particles to the dielectric oil considerably enhanced the MRR, MH, and decreased the SR of the milled micro-channel. Taguchi’s grey relational analysis (GRA) and grey-desirability approach have been applied for multi-response optimisation to find the maximum MRR, MH, and minimum SR. It is discovered that the grey-desirability method improves all the responses. The Field emission scanning electron microscopy (FESEM) micro-graphs confirm defect-free mirror-like surface finish at the optimal grey-desirability setting. The X-ray diffraction (XRD) analysis discovered the formation of oxides and hardened phases in the machined surface. The application of graphene enhanced the recast layer thickness and reduced the indentation depth at subsurface region. The nano indentation test validates the rise in nano hardness and elastic modulus at the grey desirability optimal setting compared to the initial machining condition.

Investigation on femtosecond laser combined with dynamic wet etching machining of SiC/SiC

SiC/SiC (Silicon Carbide fiber reinforced Silicon Carbide) is widely used in aerospace and gas turbine fields due to its excellent resistance to high temperature, corrosion and low density. However, the difficult processing of SiC/SiC is the main factor limiting its further application. To address these issues, this paper proposes a novel method for processing SiC/SiC using femtosecond laser combined with dynamic wet etching. A comparative analysis of the micro-pore morphology and elemental composition obtained through processing in air, water, and NaOH solution is presented. Demonstrates the excellent surface quality achieved with NaOH processing, which effectively reduces defects such as recast layers and microcracks. The results suggest that the operating mechanism involves the combined effects of a wet-oxygen coupling environment, high-temperature decomposition, localized chemical wet etching, and the influence of the liquid layer.

Surface integrity analysis of Si3N4 under cryogenic assisted femtosecond laser ablation

Femtosecond laser is suitable to process Si3N4, but heat effect forming during machining process could degrade the performance of specimen. To reduce heat damage, in this study, the effects of cryogenic assisted laser machining on the surface quality and micro-structures of Si3N4 was investigated. The femtosecond laser was employed to ablate Si3N4 at various low temperatures, accompanied with comprehensive analysis of the surface roughness, material removal rate and SEM topography. To further illustrate the formation mechanism of surface structure, finite element analysis was conducted. Results indicated that while low temperature exerted negligible effects in single-layer ablation, multi-layer laser machining benefits from improved surface quality. Low temperature mitigated thermal effects and reduced the recast layer area, resulting in decreased surface roughness. The lowest surface roughness was obtained during the machining of the specimen at −60 °C of 1.072 μm, representing a 54.6 % reduction compared to ambient air machining. However, further decreasing the temperature below −60 °C led to an increase in surface roughness. This was attributed to the combined effects of Gaussian beam energy distribution and low temperature, resulting in incomplete ablation of the surface region between two scanning pitches, thereby decreasing surface quality. This research provides valuable insights into the cryogenic assisted femtosecond laser machining.

Micro-electrical discharge machining of nitinol alloy using coated electrode and multi-energy field

ABSTRACT Nitinol alloys are widely utilized across various fields owing to their exceptional elasticity and shape memory characteristics. Their low thermal conductivity, high strength, and high toughness pose significant challenges to conventional machining technologies. To address these challenges, several non-conventional machining processes such as electrical discharge machining have been developed. This study introduces an innovative approach that combines the use of insulated coated electrodes with multi-energy field-assisted electrical discharge machining to improve the application of electrical discharge machining in machining deep microporous. We investigated the effects of the insulated electrode and multi-energy field on surface morphology, taper accuracy, diameter cutting, and the thickness of the recast layer in detail. The findings suggest that the insulated coated electrode combined with multi-energy field-assisted electrical discharge machining achieves better taper accuracy and lower diameter cutting, resulting in a smoother surface and a more uniform, thinner recast layer compared to traditional electrical discharge machining.

Effect of atomization amounts on electrical discharge ablation machining and electrochemical machining

ABSTRACT This study investigated the impact of varying atomization amounts on composite machining involving both atomized electrical discharge ablation machining and electrochemical machining (EDAM-ECM). Additionally, this study examined the effects of different atomization amounts on the material removal rate, relative electrode wear rate, processing waveforms, surface roughness, surface morphology and elements, and the EDAM-to-ECM ratio. Moreover, a theoretical model for describing the material removal process in composite processing was developed. Furthermore, the effect of the ECM ratio on the processing results was quantitatively analyzed through the integration of statistical circuits with a formula for calculating recast layer thickness. The model was used to predict and select the optimal atomization amounts required to achieve recast layer removal during processing. The results revealed that at an atomization amount of 200 mL/min, 16.7% of the total material removal was attributable to ECM, indicating the successful removal of the recast layer. At this atomization amount, the fabricated sample maintained a machining precision of 0.02 mm.

Machining of micro-hole on nitinol alloy by UV-MFEDM process

ABSTRACT Nitinol alloy is widely utilized across various industries due to its special properties. In this paper, the compound effects of two kinds of energy fields on material removal rate (MRR), hole wall quality, machining accuracy, and recast layer in ultrasonic combined magnetic field assisted EDM (UV-MFEDM were studied and analyzed. In addition, the influence of magnetic field intensity on the efficiency and accuracy of micro-hole machining is analyzed systematically. The results show that the surface quality of the micropore is significantly improved, the MRR is increased by 31.6%, the taper of the micropore is reduced by nearly 30%, the overcut diameter is reduced by nearly 23%, the recast layer is more uniform and the thickness of the recast layer is reduced by nearly half. Appropriate magnetic field intensity proves beneficial for improving micro-hole machining efficiency while reducing both taper angle and diameter overcut of micro-holes.

Performance analysis of powder-assisted micro-drilling operation using micro-EDM

Miniaturization is governed by the precise and accurate micro-machining operations of various applications. Micro-EDM has emerged as a feasible method for attaining microscale high-precision drilling. The present paper aims to conduct an experimental investigation for drilling micro-holes on copper using the Alumina (Al2O3) powder mixed Micro-EDM technique. Process parameters, including voltage, feed rate, and powder concentration, are varied in experimentation to evaluate their impact on response measures like MRR, TWR, taper angle, and aspect ratio. ANOVA determines the individual contribution of process parameters on each response measure. Voltage is the primary factor influencing MRR (93.5%), TWR (58.24%), and aspect ratio (67.3%), whereas the interaction effect of voltage with powder concentration primarily affects the taper angle (32.36%). Furthermore, the GRA method has optimized the multiple parameters for different responses. The optimum combination of parameters was obtained at a voltage of 125 V, powder concentration of 0.8 g/L, and tool travel speed of 9 µm/s at which better responses are received. The results obtained from FESEM analyses indicate that utilizing alumina (Al2O3) Nano-powder in the dielectric fluid leads to improved effectiveness and reduces the formation of micro-cracks, and micro-voids. Furthermore, the formation of recast layer is reduced by 36.49% as compared to without powder mixed EDM oil during micro-drilling operations.

Modeling and control of electrical discharge wire sawing of single-crystal silicon

Electrical discharge wire sawing (EDWS) is a new composite processing method that combines wire electrical discharge machining with fixed abrasive wire sawing. During processing, relying on the grinding effect of the abrasive grains, craters and recast layers generated by discharge are removed. The surface roughness of the workpiece is reduced while the cutting efficiency is improved. In this study, the relationship between discharge voltage and workpiece surface roughness in composite machining is investigated. A single-input single-output control system model with applied resistance as the input and discharge voltage as the output is established. Based on the theory of system identification and parameter estimation, the order of the model is identified by calculating the variance of the model residuals and using the F-test method. The model parameters of the control system are estimated online using a recursive least squares algorithm with a forgetting factor. A generalized predictive controller is designed on the basis of the predictive control theory and the identified discharge voltage control system model. Using LabVIEW software, a discharge voltage prediction control system is constructed for the processing of single-crystal silicon by EDWS, and its prediction control performance is experimentally verified. The results show that the discharge voltage control system designed in this study can successfully control the composite machining of single-crystal silicon in real time. Under the same machining conditions, the surface roughness of the workpiece machined with predictive control was 23.5 % lower than that without predictive control.

Processing characteristics and ablation mechanism of CMC-SiCf/SiC by rotational thirteen-beam coupling nanosecond laser

Silicon carbide fiber reinforced silicon carbide ceramic matrix composite (CMC SiCf/SiC) has the advantages of high temperature resistance, corrosion resistance, high strength, low density, and oxidation resistance. It is a high-performance advanced material in aerospace, energy and other fields. However, due to its high hardness, brittleness and anisotropy of fiber structure, the research on application-oriented high-quality processing technology has become a hot issue. In this paper, a new process of rotational thirteen-beam coupling nanosecond laser processing of CMC-SiCf/SiC was studied. The rotational thirteen-beam coupling ablation experiments were carried out on CMC-SiCf/SiC workpiece. A laser beam is divided into thirteen beams and rotated around the beam center by using a beam splitter element. The morphology, structure and composition of ablation holes at different speeds were observed and analyzed by laser confocal microscope, scanning electron microscope, and X-ray energy dispersive spectrometer. It is found that the characteristics of rotational beam coupling have a significant effect on the laser ablation morphologies. The results show that the ablation region of CMC-SiCf/SiC is elliptical due to the fast heat transfer of fibers. The energy density distribution of the waist section of the Gaussian like beam after beam coupling is similar to the “W" shape, and the central energy is lower than the surrounding energy, and the ablation holes also show a similar “W" shape. With the increase of rotational speed, the hole depth first decreased and then increased, the hole diameter and roundness first increased and then decreased, and the hole section was “W" shaped. The ablation area can be divided into five parts: the white granular SiO2 solid coverage area, the recast layer, the lower recast layer, the molten layer, and the heat affected zone. The rotational characteristics will make the reaction intensity of the whole ablation area more uniform in the circumferential direction. The formation mechanism and element distribution of each part were explored. The research work in this paper will provide a new technical way for the high-performance application of CMC-SiCf/SiC.

Laser ablation behavior and mechanism of Cf/C–SiC composites under different laser energy densities

Ceramic matrix composite (CMC) is typical difficult-to-machine material, laser assisted machining (LAM) is an effective method to solve the problem of poor machinability, and a deep understanding of the interaction between laser and material can lay a foundation for LAM. Aiming at the unclear mechanism of microstructure formation, crack propagation and material hardness evolution of laser-irradiated CMC, laser ablation behavior and mechanism of Cf/C–SiC composites under different laser energy densities were studied in this paper. The results show that Cf/C–SiC presents two different states of modification and ablation under irradiating. In modified state, fiber interface in central area is oxidized, and crystal transformation occurs. Amorphous Si–O–C, Si and spherical SiO2 exist in edge deposition area, and continuous phase disappears in heat affected zone. In ablative state, carbon nanosheets and clusters are formed in ablation groove. Surface of convex and deposition area are composed of sedimentary basement and clusters, and there are recast layer and heat affected zone in cross section. When thermal stress exceeds interfacial bond strength and critical matrix stress, the fiber interface debonding and matrix cracking occur, and both transgranular and intergranular fracture exist in the matrix. When laser scanning direction is perpendicular to fiber extension, crack propagation can be inhibited. The propagation and intersection of cracks and coarsening of SiC crystal phase in heat affected zone lead to the decrease of matrix microhardness. The results of this study can be used to provide references for parameters selection and theoretical support for LAM of CMC.

Controlling recast layer and material removal in reverse µEDM for sustainable fabrication of microelectrode arrays

Microelectrode arrays (MEAs) are essential for researching neurons and heart tissue because they record and stimulate neuronal activity. For manufacturing MEAs on conductive materials, reverse microelectrical discharge machining, or reverse µEDM, presents a viable method. However, achieving precise MEAs requires control over recast layers generated during micromachining. This study focuses on recast layer thickness (RLT) and material removal rate (MRR) as key performance indicators for sustainable reverse µEDM fabrication of MEAs. RLT affects surface stability, while MRR influences energy consumption and cost. Optimising these responses depends on three input factors: feed rate, capacitance, and voltage. ANOVA analysis reveals that capacitance is crucial in both MRR and recast layer thickness (RLT) in reverse µEDM, contributing to 88.71% and 94.04% simultaneously. A hybrid artificial neural network-genetic algorithm for global optimisation was employed. The optimised parameters 46.5nF capacitance, 110 V voltage, and 5 µm/sec feed yielded a minimum RLT of 1.58 µm and a maximum MRR of 0.3 mm³/min. These advancements signify significant improvements in the precision and efficiency of MEAs fabrication through reverse µEDM, contributing to its sustainable implementation.

Machining efficiency and geometrical accuracy on micro-EDM drilling of titanium alloy

ABSTRACT In the current study, micro-electric discharge drilling (µEDD) is conducted on a titanium grade 2 alloy using a tungsten carbide (WC) tool electrode of 496 µm diameter. Capacitance, voltage, and feed rate are selected as machining variables to conduct the experiments based on the full factorial experimental design method. Overcut, material removal rate (MRR), circularity, and hole taper are considered as performance measures. Furthermore, overall evaluation criteria (OEC) is utilized for multiple-objective optimization by allotting varying and equal weight percentages to each response measure. The results of OECs are compared with a revolutionary heuristic multi-objective genetic algorithm (MOGA), resulting in a similar optimal parametric combination and close response measures are obtained. Micrographic investigation demonstrates that at lower capacitance and voltage levels, there is less burr formation, recast layer, and circularity error. Moreover, FESEM and EDS analyses are employed to investigate the machined surface topology and elemental composition respectively.

Experimental investigation on the surface quality of WEDM machined 20MnCr5 steel for gear application

This experimental study investigates the Wire-cut Electrical Discharge Machining (WEDM) of 20MnCr5 steel, a low alloy steel grade material which is intended for the production of gears, shafts and other parts which need high surface hardness and wear resistance. WEDM is a crucial manufacturing process for producing gears, shafts, spindles, and various mechanical components. The investigation focuses on three key performance parameters: profile error, material removal rate (MRR), and surface roughness (SR), employing five WEDM parameters—wire feed (Wf), wire tension (Wt), servo voltage (SV), discharge arc-off time (Toff), and arc-on time (Ton) - by employing the Taguchi L27 orthogonal array. The study reveals that, in comparison to arc-on time and servo voltage, wire feed rate and tension have a lesser impact. Higher arc-on time and servo voltage result in increased profile error, while reduced wire tension values elevate surface roughness. Recast layer formation has been explored under different WEDM input parameters, revealing its dependence on arc-on time, voltage, wire tension, and feed rate. Higher voltage leads to uneven surfaces with larger globules and deep craters, contributing to a thicker recast layer at higher arc-on time and servo voltage.

Plasma characteristics and material erosion mechanism in multi-channel wire electrical discharge machining

Multi-channel wire electrical discharge machining (MC-WEDM) is an advanced and high-efficiency machining technology, but its material erosion mechanism remains unclear. In this study, dual-channel wire electrical discharge machining was utilized as a case study to investigate the impact of the plunging current on both the plasma characteristics and material erosion under complex discharge conditions. Force analysis was conducted on the charged particles in the plasma, revealing that the plunging current can influence the trajectory of the plasma by modifying the self-magnetic field. The particle tracking method was employed to simulate the motion of electrons, revealing that in MC-WEDM, electrons exhibited a larger and more uniform distribution. The evolution of the plasma within a single-pulse discharge was observed using high-speed photography technology, and the discharge signals collected from different channels were analyzed. It was observed that the plasma in MC-WEDM experienced more intense back-and-forth sweeping on the workpiece surface, facilitating the ejection of molten metal from the molten pool. The oscillating plasma exhibits a larger processing area and a more uniform distribution of energy, resulting in the formation of larger and shallower discharge craters. Furthermore, the influence of the amplitude and time point of the plunging current on the volume and area of the discharge craters was summarized. Finally, MC-WEDM significantly reduced the occurrence of holes and micro-cracks and exhibited a thinner recast layer in the continuous discharge experiment.

Study on Forming Mechanism of the Recast Layer on the Workpiece Surface during Micro EDM.

In comparison to conventional EDM, micro EDM distinguishes itself through its brief discharge duration, narrow discharge channel radius, and concentrated energy density. However, there remains a paucity of comprehensive research on the surface formation characteristics in this domain. This paper delves into the formation mechanism of the recast layer in micro EDM workpieces, scrutinizing the primary factors that influence the formation process and the morphological attributes of the recast layer. We conducted a series of single-pulse experiments and micro EDM trials. Utilizing surface fitting tools, our experimental findings facilitated the derivation of a relational expression between the recast layer thickness of high-speed steel and the discharge parameters in micro EDM. Notably, when the energy is below 100 μJ, the recast layer thickness remains under 10 μm. Specifically, at an energy level of 16 μJ, opting for a smaller capacitance of 2200 pf and a higher voltage of 120 V in micro EDM results in a thinner recast layer. This study serves as a cornerstone for future efforts aimed at controlling and assessing the surface morphology of micro EDM.

Study on the Effect of Electrolytes on Processing Efficiency and Accuracy of Titanium Alloy Utilizing Laser and Shaped Tube Electrochemical Machining.

Electrochemical machining (ECM) has become more prevalent in titanium alloy processing. However, the presence of the passivation layer on the titanium alloys significantly impacts the performance of ECM. In an attempt to overcome the passivation effects, a high-temperature electrolyte or the addition of halogen ions to the electrolyte has been used. Still, it often results in compromised machining accuracy and surface roughness. This study applied laser and shaped tube electrolytic machining (Laser-STEM) for titanium alloy drilling, where the laser was guided to the machining zone via total internal reflection. The performance of Laser-STEM using different types of electrolytes was compared. Further, the effects of laser power and pulse voltage on the machining side gap, material removal rate (MRR), and surface roughness were experimentally studied while drilling small holes in titanium alloy. The results indicated that the use of passivating electrolytes improved the machining precision, while the MRR decreased with an increase in laser power during Laser-STEM. The MRR showed an increase while using aggressive electrolytes; however, at the same time, the machining precision deteriorated with the increase in laser power. Particularly, the maximum feeding rate of 6.0 mm/min for the tool electrode was achieved using NaCl solution as the electrolyte during Laser-STEM, marking a 100% increase compared to the rate without the use of a laser. Moreover, the model and equivalent circuits were also established to illustrate the material removal mechanisms of Laser-STEM in different electrolytes. Lastly, the processing of deep small holes with a diameter of 1.5 mm, a depth of 38 mm, and a surface roughness of Ra 2 µm was achieved via Laser-STEM without the presence of a recast layer and heat-affected zones. In addition, the cross-inner flow channels in the titanium alloys were effectively processed.

Hole formation mechanisms in double-sided laser drilling of Ti6Al4V-C/SiC stacked materials

This is the first investigation on the potential of doubled-sided laser drilling for hole making in Ti6Al4V-C/SiC, a hard-to-machine stacked structure that holds critical significance in high-temperature structural applications. While previous literature reported laser drilling-induced microstructural change in Ti6Al4V and C/SiC single sheets respectively, a comprehensive understanding of the melt pool formation process and its influence on hole morphology/quality is still lacking. The complexity increases when Ti6Al4V is coupled with C/SiC in a stacked structure, highlighting a significant yet understudied knowledge gap in understanding the intricate material interactions at the interface. Here we present a multifaceted study combining novel computational fluid dynamics (CFD) modeling approach with ablation mechanism investigation through advanced microstructure analysis. A hybrid CFD modeling strategy integrating volume of fluid method and level set method has been developed to successfully simulate the evolution of hole shape, recast layer formation, and melt pool flow behaviour in Ti6Al4V-C/SiC. This model provides comprehensive insights into molten pool dynamics under various laser drilling conditions, fostering a fundamental understanding of the mechanism that drives recast layer formation and influencing surface quality. To validate our modeling outcomes, extensive experimental investigations were undertaken across a range of laser drilling conditions. Whenever possible, samples were analysed using advanced materials characterization techniques, including scanning electron microscopy, energy dispersive spectroscopy, and electron backscatter diffraction, to elucidate the microstructural evolution within the recast layer and the formation of the heat-affected zone. Whenever possible, the results were also compared with single side drilled Ti6Al4V-C/SiC stacks, Ti6Al4V or C/SiC single sheets (i.e., the benchmark references). Our experimental findings align well with the modeling results, systematically illustrating that doubled-sided laser drilling of the stacked structure outperforms the conventional single-sided laser drilling in terms of hole morphology, surface roughness, and reduced recast layer formation. Despite these promising results, the proposed technology is currently limited to laboratory scales and lacks capacity in manufacturing certain parts with complex geometry. Future outlook has therefore been proposed with potential solution to address these challenges and enable real world applications in future.

A Superhydrophobic Surface on a Superalloy Substrate with Properties of High Mechanical Strength and Self-Cleaning of Carbon Deposition.

Laser processing is an efficient method for fabricating a superhydrophobic surface and has attracted much attention due to its multifunctionality. However, excessive laser processing, such as laser beam overlap and multiple scans, generates both a thick, brittle recast layer and a thin material thickness, thereby greatly reducing the mechanical strength of the substrate. In addition, there is no report on fabricating a superhydrophobic surface on a superalloy substrate whose application includes a self-cleaning property. This work proposes the fabrication of a superhydrophobic surface on a superalloy substrate with high mechanical strength by optimizing the laser processing parameters including laser power, scanning speed, line spacing, and number of scans. We found that the microstructures required by superhydrophobicity could be constructed with a single laser scan. which could guarantee a minimal loss of the mechanical strength. The fabricated superhydrophobic surface on the superalloy substrate exhibited excellent self-cleaning of carbon deposition, showing good application potential in the aero engine field.

Sinking ECDM micro-milling of micro-channels with a customized electrode

ABSTRACT Electrochemical discharge machining (ECDM) micro-milling exhibits enormous machining potential in manufacturing metal microstructures. In this paper, a novel sinking ECDM micro-milling using glycol-based electrolyte is proposed for the high-quality fabrication of metal micro-channel structures. Firstly, a novel combined process is developed for the simple and efficient preparation of micro-electrode. With the proposed method, a micro-electrode with 91.1 μm in diameter and 21.2:1 in aspect ratio is successfully machined in 47.2 minutes. Secondly, experimental research on ECDM micro-milling machining of micro-channels in glycol-based electrolyte is carried out using the fabricated micro-electrode. Experimental results show that the machined voltage significantly affects the machining quality of micro-channels. Wear analysis reveals that the bottom geometry of the micro-electrode exhibits equal wear along the axis direction with processing times increasing, and a constant length compensation strategy (1.52 μm/mm) is adopted. Finally, an S-shaped micro-channel without recast layers (Ra 0.093 μm) was successfully fabricated.

A comparative experimental study of different magnetic field intensities on electrical discharge turning of EN24 steel alloy

This comparative study investigates the effect of various magnetic field (MF) intensities on the precision machining of cylindrical workpiece of EN24 Steel alloy in the electrical discharge turning configuration. EN24 steel is a high-strength alloy commonly employed in aerospace, automotive, and general engineering applications. The objective of this research is to evaluate the impact of MF intensity on the material removal rate (MRR), tool wear rate (TWR), overcut (OC), and surface roughness ( Ra). The rotational speed of the workpiece, peak current, and pulse-on time were kept constant machining parameters throughout the experiments. The experimental results reveal that increasing MF intensity enhances MRR, OC, and surface finish. However, it is observed that higher MF intensities lead to an elevate TWR which was a negative effect on machining performance. SEM analysis was conducted on the machined surface, revealing that higher magnetic intensity resulted in the formation of a reduced recast layer and remelted debris. The findings were further supported by energy-dispersive spectrum results, which indicated a lower presence of oxide and carbide formations on the machined surface when subjected to higher MF intensity.