Uniform Dissolution Research Articles

Molecular transport of vitamin B6 from whey protein and agarose composite gels using diffusion blending law modelling

In this investigation, whey protein and agarose were employed as the phase-separated biopolymer system, with vitamin B6 acting as the diffusant. Fourier-transform infrared (FTIR) spectroscopy affirmed the absence of chemical interactions among all constituents within the experimental parameters. X-ray diffraction (XRD) analysis corroborated the uniform dissolution of vitamin B6 within the composite low-solid mixtures. Confocal scanning laser microscopy elucidated the topology of the matrix, providing tangible evidence of the phase-separated whey protein-agarose networks. Small-deformation dynamic oscillation in-shear was employed to establish a rheological blending law model, predicting the phase volume and effective concentration of the individual components (whey protein and agarose) within their respective domains. Subsequently, a diffusion study was conducted, advocating a novel blending law for molecular transport to estimate the theoretical diffusion coefficient of vitamin B6 in the composite gel by leveraging the effective concentration of each polymer within its phase. The outcomes were positively compared to the observed diffusion coefficient of the vitamin from the composite gel using UV–vis spectroscopy. These results underscore the viability of the blending-law diffusion theory in elucidating the molecular transport of hydrophilic vitamins released from aqueous biopolymer composite gels.

Anodic Dissolution Behavior of DD6 Nickel-Based Single Crystal Superalloy for Electrochemical Machining Applications

Nickel-based single crystal superalloys have been widely used in turbomachinery components. Electrochemical machining (ECM) is an essential method for shaping such high-performance alloys. Understanding the fundamentals of ECM for these alloys is crucial for the design and optimization of the process. This study investigated the anodic dissolution of DD6 nickel-based single crystal superalloy in concentrated NaCl and NaNO3 electrolytes under ECM conditions. Polarization curves showed a passive-transpassive transition behavior in both electrolytes. Galvanostatic experiments demonstrated unique current efficiency characteristics contradicting the empirical ECM knowledge. Surface analysis revealed that the anomalous current efficiency of >100% in the NaNO3 electrolyte results from the falling of γ' phases from anodic surfaces due to the preferential dissolution of the γ matrix phase. The transition from selective to uniform dissolution with increased current density and reduced electrolyte flow velocity leads to decreased current efficiency in NaNO3 electrolyte. The removal of both γ and γ' phases depends entirely on electrochemical dissolution in NaCl electrolyte, ensuring that current efficiency maintains a normal value. A schematical anodic interface model was proposed to describe the dissolution behavior.

Titanium Alloy Ti-6Al-4V Electrochemical Dissolution Behavior in NaNO3 and NaCl Solutions at Low Current Density

Jet electrochemical micromilling (JEMM) exhibits significant potential for high-efficiency and high-quality machining of titanium alloy microstructures. However, during the JEMM process, the machined surface of the workpiece inevitably experiences stray current attacks at low current levels. Due to the formation of a dense passive film on the surface of the titanium alloy under electrochemical action, stray corrosion occurs on the machined surface. Hence, the electrochemical dissolution behavior of titanium alloys at low current densities directly impacts both machining efficiency and quality. This study first analyzed the effects of electrolyte composition and current density on the transpassive potential, breakdown of the passive film, current efficiency, and the dissolved surface on Ti-6Al-4V. The transpassive potential and electrochemical impedance of Ti-6Al-4V were found to be lower in NaCl solution than in NaNO3 solution. In addition, lower current densities enabled higher current efficiency and resulted in a more uniform and flat dissolution surface. Subsequent experiments used these two solutions for JEMM of complex-shaped microstructures on Ti-6Al-4V. The findings demonstrated that, compared to the NaNO3 solution, the use of NaCl solution increases the material removal rate by approximately 30%, enhances the aspect ratio by about 26%, and reduces surface roughness by roughly 58%. This indicates that employing NaCl solution can lead to superior machining efficiency and quality.

Enhancing the anodic dissolution uniformity of dendritic-structured refractory high entropy alloys using a split electrolytic cell with a deep eutectic solvent

The attainment of uniform anodic dissolution in dendritic-structured refractory high entropy alloys (RHEAs) during the electropolishing process is essential for their utilization in high-precision components. Nevertheless, the intricate microstructures of these materials impede uniform dissolution, resulting in suboptimal surface quality. In this work, based on a choline chloride-based deep eutectic solvent and suitable polarization parameters selected by linear scanning voltammetry, a split electrolytic cell (SEC) was proposed to alter the traditional integrated electrolytic cell (IEC) to enhance the anodic dissolution uniformity of dendritic-structured RHEAs. A much smoother surface with Ra of 0.233 μm and a smaller height discrepancy of 0.8 μm was obtained, compared to those processed in IEC at the same condition. The non-uniform anodic dissolution was mainly attributed to the cathode-forming (hydroxide ion (OH−), dissolution of tungsten (W) in the dendrite region under the attack by OH−, and the formation of by-product, i.e., the water molecule. The positive impact of SEC on dissolution uniformity could be ascribed to its role in inhibiting OH− from interacting with the anode, as well as to the enhancement of solution acidity on the anode side, which facilitated the dissolution of metal oxides. The suggested reaction pathway was subsequently validated through experiments with controlled water concentration and assessing of electrochemical kinetics. Finally, the effects of SEC under different parameters were demonstrated. This work provides valuable insight into the precise, micro/nanoscale manufacturing and green electrochemical surface finishing of RHEAs in the future.

Investigation of SDS on Corrosion Behavior and Discharge Performance of AZ31B Magnesium Alloys in Aqueous Magnesium Air Batteries

To address the issue of high self-corrosion rate of Mg anodes in seawater batteries leading to low discharge efficiency, the green inhibitor, sodium dodecyl sulfate (SDS), was utilized to enhance the discharging performance of AZ31B alloy. The addition of SDS in a 3.5% NaCl solution led to a reduction in the corrosion rate of AZ31B alloy due to the formation of S-containing compounds. During the continuous-discharging period, the addition of 0.05 M SDS increased the anodic utilization efficiency from 64% to 81% and the specific energy density of the entire battery elevated from 1280 to 1912 mAh g−1 (an increase of 49%). The enhancement of the discharge performance of AZ31B Mg alloy in a 3.5% NaCl solution by SDS can be attributed to three aspects: reducing the negative difference effect of the Mg alloy, decreasing the accumulation of corrosion products on the surface of the Mg alloy, and promoting a more uniform dissolution of the Mg alloy.

Gold and Gold Alloys Electropolishing in Choline Chloride-Glycerol Deep Eutectic Solvents

Electropolishing (EP) is a finishing technique used to reduce the roughness of metallic surfaces while enhancing their brightness. This process enables the treatment of complex shaped parts and reduces processing time compared to conventional mechanical polishing methods. Electropolishing of precious metals typically requires the use of electrolytes containing cyanides and other toxic compounds, which reduces its attractiveness from an industrial perspective. Deep Eutectic Solvents (DES) are emerging as a good alternative for the chemical and electrochemical dissolution of valuable metals, like gold, silver and copper. However, their use in the specific context of electrochemical polishing of precious alloys has not been considered so far. This work aims to evaluate the effectiveness of choline chloride-based DES in electropolishing 18K gold alloys. Their performance will be assessed in terms of roughness reduction, brightness enhancement and color preservation, all characteristics associated with the presence of a uniform dissolution.

Electrical conductivity model for reactive porous media under partially saturated conditions with hysteresis effects

The electrical conductivity of a porous medium is strongly controlled by the structure of the medium at the microscale as the pore configuration governs the distribution of the conductive fluid. The pore structure thus plays a key role since different geometries translate in variations of the fluid distribution, causing different behaviors measurable at the macroscale. In this study, we present a new physically-based analytical model derived under the assumption that the pore structure can be represented by a bundle of tortuous capillary tubes with periodic variations of their radius and a fractal distribution of pore sizes. By upscaling the microscale properties of the porous medium, we obtain expressions to estimate the total and relative electrical conductivity. The proposed pore geometry allows us to include the hysteresis phenomenon in the electrical conductivity estimates. The variations on these estimates caused by pore structure changes due to reactive processes are accounted by assuming a uniform dissolution of the pores. Under this hypothesis, we describe the evolution of the electrical conductivity during reactive processes. The expressions of the proposed model have been tested with published data from different soil textures, showing a satisfactory agreement with the experimental data. Hysteretic behavior and mineral dissolution are also successfully addressed. By including hysteresis and mineral dissolution/precipitation in the estimates of the electrical conductivity, this new analytical model presents an improvement as it relates those macroscopic physical phenomena to its origins at the microscale. This opens up exciting possibilities for studies involving electrical conductivity measurements to monitor water movement, and hysteretic and reactive processes in porous media.

Unraveling the Deposition and Dissolution Behavior of the Ag-Modified Li Surface Based on Electrochemical Atomic Force Microscopy.

Lithium is a promising anode material for advanced batteries because of its high capacity and low redox potential. However, its practical use is hindered by nonuniform Li deposition and dendrite formation, leading to safety concerns in Li metal batteries. Our study shows that Ag-based materials enhance the uniformity of Li deposition on Ag-modified Li (AgLi) surfaces, thereby addressing these key challenges. This improvement is due to the strong affinity of Ag for Li, which promotes uniform deposition and dissolution. Additionally, the AgLi surface demonstrated an improved cycling stability, which is crucial for long-term battery reliability. Emphasizing our analytical approach, we utilized comprehensive techniques such as Kelvin probe force microscopy (KPFM) and electrochemical atomic force microscopy (EC-AFM) to locally analyze the electrical properties and unravel the Li deposition/dissolution mechanisms. KPFM analysis provided crucial insights into surface potential variations, while EC-AFM highlighted topographical changes during the Li deposition and dissolution processes, contributing significantly to the development of safer and more efficient Li metal batteries.

Role of combinative In and Sm additions in tailoring the discharge performance of extruded AZ31 alloys as anodes for seawater batteries

The discharge behaviors of AZ31 alloys, modified by the addition of In and Sm elements in conjunction with equal channel angular pressing (ECAP) processing, were systematically explored. The incorporation of In suppressed the formation of cathodic second phases. In contrast, Sm promoted the precipitation process and therefore led to higher microstructure uniformity following ECAP processing. The solid-solution In contributed to the activated dissolution of Mg matrix and the inhibited hydrogen evolution during discharge, while Sm was beneficial for the uniform dissolution and the alleviation of chunk effect. The results indicated that the 12-pass ECAP processed AZ31-In-Sm anode revealed the most enhanced discharge performance with a discharge voltage of 0.889 V and a utilization of 66.94% at 100 mA cm−2. This improvement can be primarily attributed to the combined effects of the decreased precipitations of cathodic phases by In addition and the enhanced microstructure homogeneity by Sm addition, collaborated with significant microstructure refinement.

Study on the effect of aging heat treatment temperature on the microstructure and properties of soluble Al-Zn-Mg-Ga-In-Sn aluminum alloys in solid solution state

This study aimed to develop a soluble aluminum alloy material for isolation tools, characterized by high hardness, high tensile strength, and low dissolution rate. To achieve this, the Al-Zn-Mg-Ga-In-Sn soluble aluminum alloy was cast at high temperatures using a medium frequency metal induction melting furnace. The effects of different aging heat treatment processes on the mechanical properties and dissolution performance of the Al-Zn-Mg-Ga-In-Sn soluble aluminum alloy, which had undergone a solution heat treatment at 470℃ for 12 hours followed by air cooling to 25℃, were investigated. The results indicated that after aging heat treatment at 175℃ for 2 hours followed by air cooling to 25℃, the alloy exhibited uniform grain size, averaging 35±2μm. The precipitated phase Mg2Sn had an average size of 7.6±1.0 μm, with fewer in number, primarily located at the grain boundaries. Furthermore, the alloy demonstrated excellent mechanical properties, including a tensile strength of 334±1 MPa, yield strength of 226±1 MPa, and elongation of 16.6±0.5 %. Additionally, its hardness reached 91±3 HB. The dissolution rate in 90℃ distilled water was 1.6±1.0 g·h−1·cm−2, with the alloy surface showing relatively uniform dissolution characteristics during the process, and a dissolution depth of 741±5 μm.

Pore-Scale Numerical Simulation of Acid-Rock Reaction Processes in Carbonate Reservoirs.

In the process of acidizing carbonate reservoirs, dissolution is employed for reservoir modification to enhance recovery rates. This study establishes a numerical model at the pore scale for acid-rock reaction flow based on a microscopic continuum medium model, integrating phase-field theory and component transport models. Subsequently, the results of the Darcy-Brinkman-Stokes model are compared to those of the arbitrary Lagrange-Euler method to validate the accuracy of the model. Finally, the flow behavior of the acid solution at the pore scale and the complex dissolution mechanisms in carbonate reservoirs are analyzed. The research indicates that the microscopic pore-scale dissolution in carbonate reservoirs mainly manifests as five dissolution modes: uniform dissolution, compact dissolution, conical wormholes, dominant wormhole, and ramified wormholes. Different distributions of microfractures will alter the flow state of the acid solution and the rock-acid reaction process within the pores. Once the wormhole breakthrough occurs, there is an increased probability of acid flow through the wormhole to the outlet, leading to a decrease in the effectiveness of the acidizing carbonate reservoirs. A proper understanding of pore-scale acid-rock reaction laws is of great significance for the development of carbonate oil and gas reservoirs.

Dual modulation of electrolyte inner solvent structure and anode interface for high performance alkaline Al-air battery

In this work, we propose a Water-in-salt electrolyte based on concentrated ionic additive for Al-air batteries, aiming at inhibiting the unexpected severe hydrogen evolution self-corrosion. Computing calculations and experimental characterizations consistently confirm that the additive can significantly affect both the solvent structure and anode interface. A stronger H-bonding network is reconfigured and formed in the electrolyte, thus leading to a dramatic decrease in free water content and activity. Besides, the adsorption behavior of used additive molecules on Al anode surface plays an activating and stabilizing role, which is conducive to promoting the uniform dissolution of Al anode and improving the electrochemical performance. Owing to this dual modulation, the electrolyte system endows Al-air battery with extremely low self-corrosion rate (reduced by 89.6%) and remarkable discharge capacity of 2623 mAh/g.

Macro and micro-scale material removal mechanisms during ECM/hybrid laser-ECM of a passivating multiphase NbC–Ni cermet

Electrochemical machining (ECM) is a non-contact and athermal machining process where the material removal is accomplished through controlled anodic dissolution of the workpiece governed by Faraday laws. ECM process has been hybridized with several other processes for improving material processing windows. Hybrid laser electrochemical machining (LECM) synergistically applies electrochemical and laser process energies with added benefits of escalated reaction kinetics leading to enhanced transpassive dissolution, weakening of passivation layer, process localisation and uniform dissolution. The laser energy acts as a localised and controllable heat source thereby offering multi-fold processing benefits. For alloys and cermets, a characteristic surficial fingerprint is the presence of inhomogeneous multiphase dissolution and sporadically distributed passivation layer, necessitating addition of aggressive reagents in electrolytes. LECM has the potential to addresses these challenges while processing in pH neutral electrolytes. Previous works have very limited analysis on the macro and micro removal mechanisms while processing relevant strategic materials and multitude of applications of LECM remain unexploited. Therefore, this work presents in-depth investigations into macro and micro-scale material removal mechanisms of ECM/LECM on sintered niobium carbide with nickel binder (NbC–Ni), which is a potential cobalt-free alternative to tungsten carbide. The results revealed new insights into the removal behaviour of the constituent phases which differed from the first principles and their interaction with the laser. During ECM, the Ni phase dissolved preferentially and influenced the surface pattern and particle breakout which was reduced with laser assistance. The surface evolution characteristics were also analysed based on the ridge-crevice pattern. Additionally, the weakening of passive layer was correlated with the pulse analysis that revealed quantitatively the different process regimes occurring during ECM and LECM. The grain level study revealed that orientation effects still exist during LECM and the grains with higher surface energy (FCC (001) vicinal planes) passivated more and dissolved less. Furthermore, the improvement in surface quality, overcut and reduction in particle breakout with LECM process makes it promising for machining newer recipes of metal carbides.

Recovery of neodymium and iron from NdFeB waste by combined electrochemical–hydrometallurgical process

The recovery of rare-earth elements and Fe from NdFeB waste has significant potential. However, conventional hydrometallurgical and pyrometallurgical processes are energy intensive, chemical consuming, and accompanied by waste emissions, resulting in low-value iron products. This study introduced a combined electrochemical–hydrometallurgical process for NdFeB waste recovery. Electrochemical analysis revealed the active dissolution of NdFeB waste under 370 mA/cm2, enabling Fe2+ reduction to Fe even in the presence of Nd3+. Electrolysis at 60 °C using Nd2(SO4)3 and FeSO4 as electrolytes, along with H3BO3 as a pH buffer, resulted in the uniform dissolution of waste, releasing Nd3+ and Fe2+ into the electrolyte, whereas Fe2+ underwent electrodeposition onto Fe at the cathode. Investigation of FeSO4 concentration revealed its influence on current efficiency, cathode-product properties, and energy consumption. When the concentration of FeSO4 was 0.5 M, a cathode product with 87.94 wt% Fe and 0.03 wt% Nd was obtained. Finally, Nd was recovered by hydrometallurgical high-temperature crystallization at 90 °C under N2 atmosphere, yielding Nd2(SO4)3·nH2O mixed crystals with 0.1 wt% Fe. The process formed a closed loop, consuming only FeSO4 and a minimal amount of H2SO4, with an energy consumption of 0.73–1.53 kW·h/kg NdFeB.

Electrochemical machining of titanium alloy blades using optimized cathode with built-in insulators

ABSTRACT The passivation characteristics of titanium alloys in electrolytes are often the main reason that impede the electrochemical reaction process. Hence, maintaining uniform electrochemical dissolution is a prerequisite for stable electrochemical machining (ECM) of titanium alloys. In this study, a novel cathode structure with built-in insulator is proposed, whichimproves machining stability of titanium alloys in ECM. Flow dynamics simulation results show that the cathodes with built-in insulator 1 or insulator 3 demonstrate more uniform flow effect. ECM experiments reveal that the optimized cathode can reduce the time of current from transition section to balance section, presenting a optimal transition time of 180 s. Compared with the original cathode, the sample surface machined using the optimized cathode is smooth without defects. Additionally, the optimal width of the non-processing stray corrosion area decreases from 603.47 μm to 214.54 μm, and 1010.47 μm to 349.25 μm. The optimal machining taper angle is 9.85°.

Bridging the gap to practicality: A green methanesulfonic acid system enhanced with synergistic additives for efficient and high-quality lead electro-refining

Green methanesulfonic acid (MSA) system offers a promising alternative to the traditional fluosilicic acid (H2SiF6) method for lead electro-refining. However, the MSA system has yet to produce efficient electro-refining process, high-quality cathodic lead and stable anodic dissolved layer concurrently, which is crucial for its practical application. Herein, we propose an MSA-based system — enhanced with Lugalvan NES (NES) and calcium lignosulfonate (CL) — for efficient and high-quality lead electro-refining. In both proof-of-concept and separate high-flux flow operations, we achieve a low energy consumption of 73.06 kWhe/t Pb and a high Faradaic efficiency of 99.11 %. Dense deposits with ultra-low grain sizes under 20 nm and high purities of over 99.99 %, and uniform dissolved layers with moderately adhesive anode mud are obtained. Theoretical simulations reveal the HOMO and LUMO energy levels of the additives and their adsorption energy on the Pb interface. Electrochemical analysis indicates a cathodic three-dimensional nucleation process and an anodic mechanism of uniform dissolution. A modular micro-kinetics model is developed to elucidate energy performance. These advances represent a significant step forward for lead electro-refining, achieving efficient operation and high-quality output while reducing energy use and surpassing the efficacy of the traditional method.

Electrochemical polishing with glycol-based electrolyte of the curved internal channels fabricated via laser powder bed fusion

Electrochemical polishing (ECP) is used to process metal additive manufacturing parts with poor surface qualities arising from powder adhesion, spheroidal effect, and step effect during forming. Conventional ECP uses stationary acid-based solutions and very low current densities, which makes it challenging to efficiently polish complex-shaped internal channels. Typically, an oxide layer forms in the conventional aqueous-based electrolyte, which prevents uniform dissolution and consequently deteriorates surface quality. In this study, we proposed a modified ECP method for polishing curved internal channels in laser powder bed fusion (LPBF) 316 L stainless steel (SS) specimens using a high-speed flow of a NaCl–ethylene glycol (EG) solution at low current densities. During electrochemical tests, LPBF 316LSS specimens did not exhibit passivation in the NaCl–EG solution, and the current efficiency was high at low current densities (i < 4 A·cm−2). The reaction mechanism of ECP LPBF 316LSS in the NaCl–EG solution was clarified by observing the experimental phenomena and testing the composition of the reaction products. The ECP experiments showed that the decrease of roughness value is directly related to the charge. A small roughness value can also be obtained at low current densities (i < 2 A·cm−2). Finally, S-shaped curved holes with a diameter of Φ3 mm were efficiently polished using a flexible cathode in the NaCl–EG solution. In the case of an aperture increase rate of only about 7 %, it would only take 400 s to drastically reduce the surface roughness value Sa from 12.73 to 12.94 μm to 2.16– 2.43 μm.

An Investigation of Gas-Fingering Behavior during CO2 Flooding in Acid Stimulation Formations

Summary CO2 flooding is emerging as a pivotal technique used extensively for carbon capture, utilization, and storage (CCUS) strategies. Acid stimulation is one common technique widely used to improve well-formation connectivity by creating wormholes. This work is motivated to investigate the gas-fingering behavior induced by acid stimulation during CO2 flooding. We present an integrated simulation framework to couple the acid stimulation and CO2 flooding processes, in which the two-scale continuum model is used to model the development of wormhole dissolution patterns. Then, sensitivity case simulations are conducted through the equation of state (EOS)–based compositional model to further analyze the CO2 fingering behavior in acid stimulation formations separately under immiscible and miscible conditions. Results demonstrate that for acid stimulation, the typical dissolution patterns and the optimal acid injection rate corresponding to the minimum acid breakthrough volume observed in the laboratory are prevalent in field-scale simulations. For CO2 flooding simulation, the dissolution patterns trigger CO2 fingering (bypassing due to the high conductivity of wormholes) in the stimulated region, and a lateral boundary effect eliminating fingers exerts its influence over the system through transverse mixing. The optimal acid injection rate varies when the focus of interest changes from the minimum acid breakthrough volume to CO2 flooding performance. The best CO2 flooding performance is always observed in uniform dissolution, and the dissolution patterns have a greater influence on the performance under miscible conditions. This work provides technical and theoretical support for the practical application of acid stimulation and CO2 flooding.

Superior specific capacity and energy density simultaneously achieved by Sr/In co-deposition behavior of Mg-Sr-In ternary alloys as anodes for Mg-Air cells

In this work, the combined addition of strontium/indium (Sr/In) to the magnesium anode for Mg-Air Cells is investigated to improve discharge performance by modifying the anode/electrolyte interface. Indium exists as solid solution atoms in the α-Mg matrix without its second-phase generation, and at the same time facilitates grain refinement, dendritic segregation and Mg17Sr2-phases precipitation. During discharge operation, Sr modifies the film composition via its compounds and promoted the redeposition of In at the substrate/film interface; their co-deposition behavior on the anodic reaction surface enhances anode reaction kinetics, suppresses the negative difference effect (NDE) and mitigates the “chunk effect” (CE), which is contributed to uniform dissolution and low self-corrosion hydrogen evolution rate (HER). Therefore, Mg-Sr-xIn alloy anodes show excellent discharge performance, e.g., 0.5Sr-1.0In shows an average discharge voltage of 1.4234 V and a specific energy density of 1990.71 Wh kg−1 at 10 mA cm−2. Furthermore, the decisive factor (CE and self-discharge HE) for anodic efficiency are quantitively analyzed, the self-discharge is the main factor of cell efficiency loss. Surprisingly, all Mg-Sr-xIn anodes show anodic efficiency greater than 60% at high current density (≥10 mA cm−2), making them excellent candidate anodes for Mg-Air cells at high-power output.

Jet Electrochemical Micromilling of Ti-6Al-4V Using NaCl-Ethylene Glycol Electrolyte.

Titanium alloys are widely used in aerospace and biomedicine because of their excellent mechanical characteristics, but these properties also make such alloys difficult to cut. Jet electrochemical micromilling (JEMM) is based on the principle of electrochemical anodic dissolution; it has some inherent advantages for the machining of titanium alloy microstructures. However, titanium oxidizes readily, forming an oxide film that impedes a uniform dissolution during electrochemical machining. Therefore, a high voltage and an aqueous NaCl electrolyte are usually used to break the oxide film, which can lead to severe stray corrosion. To overcome this problem, the present study investigated the JEMM of Ti-6Al-4V using a NaCl-ethylene glycol (NaCl-EG) electrolyte. Electrochemical testing showed that Ti-6Al-4V exhibits a better corrosion resistance in the NaCl-EG electrolyte compared to the aqueous NaCl electrolyte, thereby reducing stray corrosion. The localization and surface quality of the grooves were enhanced significantly when using JEMM with a NaCl-EG electrolyte. A multiple-pass strategy was adopted during JEMM to improve the aspect ratio, and the effects of the feed depth and number of passes on the multiple-pass machining performance were investigated. Ultimately, a square annular microstructure with a high geometric dimensional consistency and a smooth surface was obtained via JEMM with multiple passes using the optimal parameters.