Surface Quality Research Articles

Machining behaviour analysis of PBF-LB warped components with internal lattice microstructures

Metal additive Powder Bed Fusion, Laser Based (PBF-LB) manufacturing offers significant improvements in the design of complex parts of inner components areas for several sectors, from dies and moulds, to blades and aerofoils. Generating internal structures helps to move fluids, work as heat exchanges, or achieve dramatic weight relief, only possible by additive manufacturing, concretely PBF-LB. Along with these designs, sculptured surfaces and warped surfaces are also common in blades and other aerodynamic pieces. However, it is mandatory that these designs accomplish the final required mechanical properties without surface damage and non-admissible dimensional deviations. In this study, the five-axis milling of a part containing internal structures has been investigated. Two types of PBF-LB Inconel® 718 blades were manufactured, one solid and one with internal microstructures. They were finished using two types of ball-ended mills, ball and barrel-lens tooltip. The analysis of the blade with internal structures shows better machining behaviour, dynamic behaviour, and surface quality.

ANALYSIS OF SURFACE QUALITY IN BASE ACRYLIC PLASTIC USING FLAW DETECTION METHOD

Before scanning the surface of the base acrylic plastic, ten samples were selected with a surface that had undergone all stages of finishing according to the proper dental protocol and ten samples that had previously been artificially damaged with scratches using sandpaper. This study addresses the assessment of the quality of removable orthopedic appliances concerning surface polishing and detection of microdefects. The research employs a comparative analysis of reference samples of base plastic and artificially damaged samples using flaw detection analysis. Prior to scanning the surface of the base acrylic plastic, ten samples underwent all stages of finishing according to dental protocol, while another ten samples were intentionally damaged with scratches using sandpaper. The macrophotographs obtained were processed using the "Image J" program, allowing for quantitative analysis of images, enabling the evaluation of surface quality through various parameters. This included evaluating the total number of defects, as well as the average area and perimeter of the defects. Statistical analysis conducted in the JUSP program enabled comparison between the two groups of samples, identifying significant quantitative differences. Based on the prominent indicators available in the Image J program, conclusions were drawn regarding the quality of the acrylic plastic surface and the factors influencing its condition through specific mechanical defects. The proposed method of light-optical flaw detection expands the clinical assessment capabilities of removable orthopedic structures (base plastic), particularly concerning potential bacterial contamination, which can serve as a significant factor in the formation of inflammation foci on the mucous membrane of the denture-supporting oral tissues. Flaw detection analysis enables a comprehensive assessment of material surface polishing quality and the detection of surface defects that may arise during production or use, thus preventing biofilm accumulation. The experiment demonstrated the effectiveness of light-optical flaw detection and highlights the potential for its further improvement and broader implementation in clinical practice.

Correlative spatter and vapour depression dynamics during laser powder bed fusion of an Al-Fe-Zr alloy

Abstract Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron X-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced crater mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts.

Machinability of extruded H13 tool steel: Effect of cutting parameters on cutting forces, surface roughness, microstructure, and residual stresses

The production of H13 tool steel (TS) by material extrusion (MEX) is a promising method in various applications, but as-built surface roughness does not comply with the quality requirements. Hence, this study investigated the effects of cutting parameters on tool wear, cutting forces, surface quality, microhardness, structure, and residual stresses when machining H13 TS produced by MEX. Dry machining (DM) proved advantageous in certain indicators such as tool wear and cutting forces in comparison to the flood cooling (FC). The lowest surface roughness (0.08 µm) was achieved at the cutting speed of 80 m/min, feed per tooth of 0.005 mm, and FC which corresponded to a 41 % decrease compared to DM under same conditions. Surface microhardness increased by 20 % after machining, decreasing with distance from the surface. The highest compressive residual stresses were observed under FC, while the DM resulted in a 78.2 % decrease in residual stresses due to a partial annealing effect caused by higher surface temperature. Overall, DM exhibited great potential for achieving high-quality surfaces with a favorable structure and residual stresses. This study´s novelty and robustness lie in its significant contribution to practical industrial applications, such as mold and core production.

Zr-based bulk metallic glasses in PBF-LB/M: near-polished surface quality in the as-built state

AbstractThis study investigates the relationship between varying contour scanning parameters and their impact on both surface characteristics and mechanical performance of the glass-forming Zr59.3Cu28.8Al10.4Nb1.5 produced via PBF-LB/M. Near-polished surface states with Ra values below 1 µm were achieved. The study identifies increased laser power as a key factor in reducing the surface roughness, while repetitive scanning exhibits only marginal improvements in surface quality. Partial crystallization on the surface of the amorphous samples is found on the as-built surfaces. However, it appears to be confined to depths below 50 µm. Impressively, the material showcases large mechanical strength in the as-built condition, evidenced by a high flexural strength of 2.2 GPa combined with approximately 1% plastic deformation. These findings offer initial insights into optimizing additive manufacturing processes for BMGs, guiding the enhancement of both surface quality and mechanical robustness in Zr-based metallic glass fabricated via PBF-LB/M techniques.

Use of machine learning models in condition monitoring of abrasive belt in robotic arm grinding process

AbstractAlthough the aspects that affect the performance and the deterioration of abrasive belt grinding are known, wear prediction of abrasive belts in the robotic arm grinding process is still challenging. Massive wear of coarse grains on the belt surface has a serious impact on the integrity of the tool and it reduces the surface quality of the finished products. Conventional wear status monitoring strategies that use special tools result in the cessation of the manufacturing production process which sometimes takes a long time and is highly dependent on human capabilities. The erratic wear behavior of abrasive belts demands machining processes in the manufacturing industry to be equipped with intelligent decision-making methods. In this study, to maintain a uniform tool movement, an abrasive belt grinding is installed at the end-effector of a robotic arm to grind the surface of a mild steel workpiece. Simultaneously, accelerometers and force sensors are integrated into the system to record its vibration and forces in real-time. The vibration signal responses from the workpiece and the tool reflect the wear level of the grinding belt to monitor the tool’s condition. Intelligent monitoring of abrasive belt grinding conditions using several machine learning algorithms that include K-Nearest Neighbor (KNN), Support Vector Machine (SVM), Multi-Layer Perceptron (MLP), and Decision Tree (DT) are investigated. The machine learning models with the optimized hyperparameters that produce the highest average test accuracy were found using the DT, Random Forest (RF), and XGBoost. Meanwhile, the lowest latency was obtained by DT and RF. A decision-tree-based classifier could be a promising model to tackle the problem of abrasive belt grinding prediction. The application of various algorithms will be a major focus of our research team in future research activities, investigating how we apply the selected methods in real-world industrial environments.

Impact of assimilation of absolute dynamic topography on Arctic Ocean circulation

The ocean circulation is typically constrained in operational analysis and forecasting systems through the assimilation of sea level anomaly (SLA) retrievals from satellite altimetry. This approach has limited benefits in the Arctic Ocean and surrounding seas due to data gaps caused by sea ice coverage. Moreover, assimilation of SLA in seasonally ice-free regions may be negatively affected by the quality of the Mean Sea Surface (MSS) used to derive the SLA. Here, we use the Regional Ice Ocean Prediction System (RIOPS) to investigate the impact of assimilating Absolute Dynamic Topography (ADT) fields on the circulation in the Arctic Ocean. This approach avoids the use of a MSS and additionally provides information on sea level in ice covered regions using measurements across leads (openings) in the sea ice. RIOPS uses a coupled ice-ocean model on a 3-4 km grid-resolution pan-Arctic domain together with a multi-variate reduced-order Kalman Filter. The system assimilates satellite altimetry and sea surface temperature together with in situ profile observations. The background error is modified to match the spectral characteristics of the ADT fields, which contain less energy at small scales than traditional SLA due to filtering applied to reduce noise originating in the geoid product used. A series of four-year reanalyses demonstrate significant reductions in innovation statistics with important impacts across the Arctic Ocean. Results suggest that the assimilation of ADT can improve circulation and sea ice drift in the Arctic Ocean, and intensify volume transports through key Arctic gateways and resulting exchanges with the Atlantic Ocean. A reanalysis with a modified Mean Dynamic Topography (MDT) is able to reproduce many of the benefits of the ADT but does not capture the enhanced transports. Assimilation of SLA observations from leads in the sea ice appears to degrade several circulation features; however, these results may be sensitive to errors in MDT. This study highlights the large uncertainties that exist in present operational ocean forecasting systems for the Arctic Ocean due to the relative paucity and reduced quality of observations compared to ice-free areas of the Global Ocean. Moreover, this underscores the need for dedicated and focused efforts to address this critical gap in the Global Ocean Observing System.

New insights into the interpretation of the results of four point bending tests on float glass

AbstractThe four point bending test is one of the most commonly used and standardised tests to determine the mechanical properties of materials. For its use on float glass there are both the ASTM C158-02R17 and European EN 1288-3:2001 standards. However when testing float glass the results tend be a statistical muddle. This impacts the reliability of the design strength of float glass determined using four point bending tests. In an attempt to resolve this problem a series of four point bending tests were conducted which were designed to be more systematic than those previously reported in the literature and which use newly developed digital microscopy techniques for pre- and post-test analysis. By systematically testing, the test results can be divided into different groups based on air side, Sn side and source of failure, allowing the data to be divided into clear and separate statistical groups. Secondly the results can potentially be used to validate the lower bound glass strength theory proposed by Ballarini et al. (J Eng Mech 142(12):04016100, 2016). The glass specimens were industrially cut, ground, chamfered and flat polished on the long sides. Specimens were checked using advanced digital microscopy before and after testing. The results suggest that uni-modal Weibull behaviour only applies above a critical failure stress. Failures at stresses below this critical failure stress as a group have a separate and steeper Weibull slope. This supports Ballarini’s theory for a lower bound failure strength although there are important differences between the air side and Sn side of the specimens which this theory does not currently allow for. These differences seem to be inherent to the differences between the glass and the Sn sides. The results also show that the strength of cut, ground, chamfered and flat polished glass can be high but that inconsistency in process control and the irregular occurrence of surface failures are the main causes for the statistical spread. Digital microscopy can reliably measure the quality of the various surfaces and intersections of surfaces of a glass specimen but there is no absolute relation between the size of a detected defect and the probability that this defect actually leads to failure.

Study on the impact of ultrasonic vibration-assisted grinding of glass-ceramics on surface/subsurface damage mechanism

PurposeAn investigation was conducted into the impact of various process parameters on the surface and subsurface quality of glass-ceramic materials, as well as the mechanism of material removal and crack formation, through the use of ultrasonic-assisted grinding.Design/methodology/approachA mathematical model of crack propagation in ultrasonic-assisted grinding was established, and the mechanism of crack formation was described through the model. A series of simulations and experiments were conducted to investigate the impact of process parameters on crack depth, surface roughness, and surface topography during ultrasonic-assisted surface and axial grinding. Additionally, the mechanism of crack formation was explored.FindingsDuring ultrasonic-assisted grinding, the average grinding forces are between 0.4–1.0 N, which is much smaller than that of ordinary grinding (1.0–3.5 N). In surface grinding, the maximum surface stresses between the workpiece and the tool gradually decrease with the tool speed. The surface stresses of the workpiece increase with the grinding depth, and the depth of subsurface cracks increases with the grinding depth. With the increase of the axial grinding speed, the subsurface damage depth increases. The roughness increases from 0.780um/1.433um.Originality/valueA mathematical model of crack propagation in ultrasonic-assisted grinding was established, and the mechanism of crack formation was described through the model. The deformation involved in the grinding process is large, and the FEM-SPH modeling method is used to solve the problem that the results of the traditional finite element method are not convergent and the calculation efficiency is low.

PERFORMANCE ENHANCEMENT OF BRASS EDM ELECTRODES WITH CRYOGENIC TREATMENT WHILE MACHINING THE COLD WORK STEEL AISI D2

This study investigates the performance of deep cryogenically treated brass (CuZn25Al5) electrodes in the die-sink EDM process. Two different cryogenic treatment durations, 6 h and 12 h, were applied to 8 mm diameter electrodes, and their effects were compared to untreated electrodes. The machining tests were conducted under moderate and aggressive conditions. In the machining tests, the 6-h cryo-treated electrode exhibited a 16.8% increase in material removal rate (MRR) under moderate conditions and a 19.7% increase under aggressive conditions compared to the reference electrode. The 12-h cryo-treated electrode showed similar MRR values to the reference electrode but improved tool wear resistance by 9.4% under moderate conditions. The kerf angle was minimized, indicating better hole verticality, in the 6-h cryo-treated electrode group. The improvement in machining performance was attributed to the enhancement in electrical conductivity of the electrodes, which increased by 28% for the 6-h cryo-treated electrode and 20% for the 12-h cryo-treated electrode. X-ray diffraction (XRD) analysis revealed shifts in peak positions and possible phase transformations due to cryogenic treatment. Surface roughness measurements showed improved surface conditions in the cryo-treated electrodes under aggressive conditions. The results indicate that cryogenic treatment enhances MRR, reduces tool wear, and improves surface quality in die-sink EDM. These improvements are attributed to increased electrical conductivity and changes in the internal structure of the brass electrode.

Effects of process parameters and geometry on dimensional accuracy and surface quality of thin strut heart valve frames manufactured by laser powder bed fusion

AbstractLaser powder bed fusion (LPBF) is one of the most popular metal additive manufacturing technologies, which has found its applications in high-value sectors such as aerospace and biomedical devices. Some recent studies on the LPBF of stents have demonstrated its feasibility in the fabrication in thin strut structures including heart valve frames, as used in transcatheter aortic valve implantation (TAVI) for the treatment of severe aortic stenosis. The state of the art method of laser cutting TAVI frame limits the scope for novel concepts which are made possible by additive manufacturing. However, the surface quality and dimensional accuracy of LPBF parts are lower than that produced by laser cutting. To start the development of new TAVI concepts, the feasibility of manufacturing thin frames by LPBF has been investigated based on the SAPIEN 3 frame by Edwards Lifesciences. In this study, simplified frames with strut size from 0.3 to 0.5 mm have been successfully manufactured. The effects of strut size, strut angle, laser power and scan speed on the dimensional accuracy and surface quality were systemically studied. In addition, a representative SAPIEN 3 frame was manufactured and assessed with high-resolution X-ray CT scans. Good overall dimensional accuracy and low porosity were obtained for the SAPIEN 3 frame. However, inclined struts were found to have relatively low dimensional accuracy and poor surface quality.

Mathematical Analysis for Optimizing Electro Discharge Machining Parameters and Enhancing Hastelloy Machining Efficiency

This study investigates the process parameter optimisation for Hastelloy electro discharge machining (EDM). The goal of the research is to increase machining accuracy and efficiency by precisely changing the EDM process factors. The most important variables affecting tool wear, surface quality, and material removal rate are identified. In order to improve the machining performance for Hastelloy components, the research highlights the importance of factors including discharge current, pulse duration, electrode material, and dielectric fluid properties. The study's conclusions give important information about how to improve EDM procedures for this tough, corrosion-resistant hastealloy. Extensive research is conducted into the features of tool wear and their connection to process parameters in an effort to increase tool life and reduce manufacturing costs. The findings of this research offer useful data for optimising the efficiency of the Hastelloy EDM process in terms of both money and time. The growing need for high-performance components in industries including aerospace, chemical, and nuclear engineering is being addressed by this study, which intends to lay the groundwork for the development of efficient and environmentally friendly machining practises for Hastelloy. To do this, one must get a thorough comprehension of the interrelationships between the various process parameters.

High-temperature oxidation characteristics of 20CrMnTi electroplated with copper

During high-temperature forming and phase change heat treatment, the steel surface is susceptible to oxidation. This can negatively affect the surface quality of steel parts. The production of antioxidant coatings on the surface of steel parts is important for high-temperature precision forming and heat treatment. In this paper, the high-temperature oxidation tests of 20CrMnTi steel, copper, and 20CrMnTi electroplated with copper are conducted. The 20CrMnTi samples showed varying degrees of mass gain above 900 °C; the copper samples showed varying degrees of mass gain above 700 °C; and the process of mass gain for copper-plated 20CrMnTi followed the same trend as for copper during heating and holding. For heated samples of 20CrMnTi plated with copper, the copper coating was oxidized and residual copper was observed in the oxide layer. The distance between the residual copper and the surface of the sample is greater than between the residual copper and the junction of the plating layer and the substrate. Oxygen diffuses through internal defects in the material at a higher rate than copper oxidation. In this study, an oxygen diffusion model and an antioxidant protective layer model at high temperatures were suggested. The protective layer against oxidation recommended in this research is a dense coating consisting of single crystals or fine grains free of porosities and cracks.

The High Temperature Strength of Single Crystal Ni‐base Superalloys – Re‐visiting Constant Strain Rate, Creep and Thermomechanical Fatigue Testing

The present work takes a new look at the high temperature strength of single crystal (SX) Ni‐base superalloys. It compares high temperature constant strain rate (CSR) testing, creep testing and out‐of‐phase thermomechanical fatigue (OP‐TMF) testing, which represent key characterization methods supporting alloy development and component design in SX material science and technology. The three types of tests are compared using the same SX alloy, working with precisely oriented <001>‐specimens and considering the same temperature range between 1023 and 1223 K, where climb‐controlled micro‐creep processes need to be considered. Nevertheless, the three types of tests provide different types of information. CSR testing at imposed strain rates of 3.3·10‐4 s‐1 shows a yield stress anomaly (YSA) with a YSA stress peak at a temperature of 1073 K. This increase of strength with increasing temperature is not observed during constant load creep testing at much lower deformation rates around 10‐7 s‐1. Creep rates show a usual behavior and increase with increasing temperatures. During OP‐TMF loading, the temperature continuously increases/decreases in the compression/tension part of the mechanical strain‐controlled cycle (±0.5%). At the temperature, where the YSA peak stress temperature is observed, no peculiarities are observed. It is shown that OP‐TMF life is sensitive to surface quality, which is not the case in creep. A smaller number of cycles to failure is observed when reducing the heating rate in the compression/heating part of the mechanical strain‐controlled OP‐TMF cycle. The results are discussed on a microstructural basis, using results from scanning and transmission electron microscopy, and in light of previous work published in the literature.This article is protected by copyright. All rights reserved.

Ensuring the Abrasive Jet Machining Efficiency Using a Nozzle with a Perforated Insert

Ejector-cleaning devices for abrasive jet machining have various practical applications. The working nozzle is one of the device’s key elements affecting the treated surface quality. There arises the necessity for new approaches to achieving an efficiency increase in abrasive jet equipment nozzles, namely their design improvement and further development of a new, relatively cheap but effective technology for their manufacturing and maintenance. This technology should allow for the high durability of nozzles without being essential for the hardness or wear resistance parameters of the material used for manufacturing. The nozzle should be designed as a long-length perforated insert to allow for radial airflow, forcing the abrasive material (river sand) from the inner walls of the nozzle’s working surface to reduce its friction with the abrasive material. This will result in new wear-out conditions, providing an essential decrease in the wear-out of a nozzle’s working surface. The article aims to develop a more effective design for the working nozzle based on the perforated insert application. The task was set to provide a more detailed experimental and theoretical study of the processes in perforated nozzles to improve their effectiveness. The research resulted in a new design for nozzles with higher efficiency.

Enhancing Surface Integrity and Quality through Roller Burnishing: A Comprehensive Review of Parameters Optimization, and Applications.

Surface integrity is a critical aspect in ensuring the quality of components or products, particularly in industries such as automotive, aerospace, and machinery where superior surface finish and prolonged functionality of cylindrical parts are essential. Burnishing, a chip-less cold working finishing process, enhances the surface finish of machined workpieces through plastic deformation. This review paper delves into various aspects of the burnishing process and its impact on surface properties, drawing insights from multiple research projects. It explores topics including residual stresses, surface roughness, microhardness, cooling strategies, and modeling techniques. Key findings underscore the influence of burnishing parameters such as speed, feed rate, penetration depth, and number of passes on surface roughness and microhardness. Moreover, the process induces compressive residual strains on the workpiece surface, with their magnitude varying based on operational parameters. The choice of cooling methods, including kerosene, minimum quantity lubrication (MQL), cryogenic cooling, and hybrid cooling, significantly affects surface integrity. Various modeling approaches, such as Artificial Neural Networks (ANN), Adaptive Neuro-Fuzzy Inference Systems (ANFIS), and Response Surface Methodology (RSM), aid in predicting and optimizing surface characteristics. Despite the extensive discussion on surface roughness, microhardness, residual stresses, cooling methods, and modeling, out-of-roundness in the burnishing process remains understudied and warrants further investigation. This review contributes valuable insights for enhancing surface qualities in manufacturing applications and deepening our understanding of the burnishing process.

Investigation of Surface Integrity of 304 Stainless Steel in Turning Process with Nanofluid Minimum-Quantity Lubrication Using h-BN Nanoparticles

This paper investigates the influence of the concentration and particle size of h-BN nanoparticles in a nanofluid on the surface integrity of 304 austenitic stainless steel during turning, focusing on the cutting force, friction coefficient, cutting temperature, surface roughness, surface residual stress, work hardening capacity, and 3D surface topography. The results show that, compared to dry cutting, the addition of 3 wt.% h-BN nanofluid can reduce the friction coefficient on the rake face by 38.9%, lower the cutting temperature by 43.5%, decrease the surface roughness by 53.8%, decrease the surface residual stress by 61.6%, and reduce the work hardening degree by 27.5%. Two-dimensional profiles and the 3D surface topography display a more balanced peak–valley distribution. Furthermore, by studying the effect of different h-BN particle sizes in nanofluids on the surface integrity of the machined workpiece, it was found that nanoscale particles have a greater tendency to penetrate the tool–chip interface than submicron particles. Moreover, the h-BN particles in the nanofluid play a “rolling effect” and “microsphere” effect, and the sesame oil will also form a lubricating oil film in the knife-chip contact area, thereby reducing the friction coefficient, reducing the cutting force, and improving the machining surface quality.

Effective Promotion of Micro Damping of GO Hybrid PU–PF Copolymer Grinding Wheels on Precision Machining

The influence of damping and friction performance of grinding wheels on precision grinding was explored for the first time. GO hybrid PU-modified PF copolymers were prepared by in situ synthesis and adopted as a matrix for fabricating grinding wheels. FT-IR, DSC, TG, and mechanical property tests showed the optimal modification when PU content was 10 wt% and GO addition was 0.1 wt%. Damping properties were investigated by DMA, and tribological characteristics were measured by sliding friction and wear experiments. The worn surfaces and fracture morphologies of GO hybrid PU–PF copolymers were observed by SEM. Distribution of components on the worn surfaces was explored by Raman mapping and EDS. The research results revealed that the PU component tended to be dispersed around the edges of corundum abrasives acting as a buffer layer of abrasive particles, which could provide micro-damping characteristics for abrasives, making the grinding force more stable during precision machining and facilitating a smoother surface quality of the workpiece.

Optimizing the surface quality of heat-treated 2Cr13 stainless steel via electrochemical machining

The improvement of mechanical properties and surface quality was of great significance for materials. In this study, 2Cr13 stainless steel was subjected to the quenching and tempering treatment. The electrochemical machining approach was adopted for surface treatment. The results showed that the quenching and tempering treatment improved the Vickers microhardness of 2Cr13 stainless steel. The enhancement of microhardness was facilitated by the formation of tempered sorbite and grain refinement. Electrochemical machining provided high quality surfaces. The heat-treated workpice had more advantages in electrochemical machining efficiency. The polarization curves proved a downward shift of the self-corrosion potential for the heat-treated 2Cr13 stainless steel, which was strongly related to the electrochemical behavior. A mechanism model for promoting anode electrochemical dissolution was proposed.

Investigation of the influence of different types of electrolytes on the performance of the Electrochemical Discharge Machining process during micromachining of molybdenum

Electrochemical Discharge Machining (ECDM) is a hybrid process that integrates the principles of Electrochemical Machining (ECM) and Electrical Discharge Machining (EDM) to create micro-holes in both conductive and non-conductive materials that are typically difficult to machine. Given the unpredictable nature of this hybrid method, the composition of the electrolyte emerges as a critical factor influencing the accuracy and performance of the machining process. Consequently, the optimization and analysis of electrolytes are pivotal for the efficient utilization of energy during ECDM and for ensuring machining precision. This study aims to experimentally investigate the impact of various types of electrolytes and their concentrations. These are divided into two categories: neutral solutions, which include sodium nitrate (NaNO₃) and sodium chloride (NaCl), and alkaline solutions, comprising sodium hydroxide (NaOH) and potassium hydroxide (KOH), as well as a mixture of both NaOH and KOH. The evaluation metrics considered include the Material Removal Rate (MRR), Tool Wear Rate (TWR), overcut (OC), Heat Affected Zone (HAZ) and surface quality. It was observed that alkaline solutions, particularly the mixed electrolyte, resulted in higher MRR and HAZ, reduced TWR, and the production of micro-holes with minimized overcut compared to using KOH and NaOH separately or neutral solutions, while also enhancing surface quality. Further analysis using Scanning Electron Microscopy (SEM) images and Energy-Dispersive Spectroscopy (EDS) of the brass tools used with different electrolytes revealed that tools used in KOH and mixed electrolytes exhibited less wear and material erosion compared to those used in NaOH and neutral solutions.