ABSTRACT Dissolution behavior and surface integrity during the electrochemical machining (ECM) of nickel-based superalloys are vital for the performance of components. This study examines IN718, 718Plus, and Rene 65 alloys focusing on material removal mechanisms, surface morphology, intergranular corrosion, three-dimensional profiles, surface roughness, microhardness, and residual stresses. The results indicated that as the current density increased, the MRR of all three alloys increased linearly, while the current efficiency initially fluctuated before stabilizing. At low current densities, selective dissolution and intergranular corrosion resulted in rough surfaces for the alloys examined. In contrast, higher current densities produced smooth and uniform surfaces for these alloys. After electrochemical treatment, the surface microhardness of all alloys was reduced, and there was a slight decrease in residual stresses as well. These findings support the development of more precise and effective strategies for achieving higher surface integrity in the ECM of nickel-based superalloys.
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