The present workis focused on compacting, sintering, and characterization of sintered magnetic abrasive particles, which is composed of equal volume fraction of alumina and carbonyl iron powder. Powder metallurgy method is a well-developed technique for manufacturing of ferrous and nonferrous parts. AhO3–CIP composites are prepared through powder metallurgy method. Ball milling is used for mixing powders, and hydraulic Jack with die is used for compacting purpose. Solid and liquid phase sintering is performed at a high temperature tubular furnace under an inert gas atmosphere of argon. Solid and liquid phase sintering is done at 1000°C and 1545°C, respectively in proper consecutive sintering cycle. After sintering, the sintered pallets are crushed using ball miller to obtain the required size of the sintered powder. Energy Dispersive X-ray spectroscopy is used for elemental composition of all sintered powders. Vibrating sample magnetometer is used to see the magnetization of the particles. The saturation magnetization of the sintered abrasive obtained at 9–ton compaction pressure is found to be highest. Different phases of all prepared samples are studied using the X-ray diffraction technique. The morphology, as well as particle size, are studied using a scanning electron microscope. Also, the microstructure of sintered powders is studied using an optical microscope. Compression strength test of all sintered pallets is carried out using Universal Testing Machine. Bulk density of the pallets is measured using standard Archimedean principle. It is observed that the bulk density value increases with the compaction load. Micro hardness of the sintered pallets is measured using a Vickers micro hardness measuring instrument. The sintered pallet, fabricated at a compaction pressure of 9 ton shows the highest hardness.

Electrochemical micromachining (EMM) uses anodic dissolution in the range of microns to remove material. Complex shapes that are difficult to machine on hard materials can be fabricated easily with the help of EMM without any stresses on the workpiece surface and no tool wear. Fabrication of microfeatures on microdevices is a critical issue in modern technologies. For the fabrication of microfeatures, precise micro-tools have to be fabricated. In this present study, EMM milling is used for the fabrication of micro-tools. For this, an EMM setup has been designed. Tungsten carbide tools with an initial diameter of 520 µm have been selected and are electrochemically machined to reduce their diameter. The tool and workpiece are connected as anode and cathode, respectively. The electrolyte solution used for this investigation is sodium nitrate. A comparative analysis of the effect of tool rotation over both machining accuracy and surface finish has been performed.

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The study of surface texturing has been a great interest to the researcher over the last years. Surface texturing improves the property of the surface of the material in the working area. It creates a pattern of micron dimensions over the surface to influence the surface property in its working area. Several techniques are used to fabricate these micro dimensions. Electrochemical micromachining (EMM) emerges as a new technique with several benefits. This review paper highlights the advantages of EMM over other processes and discusses different methods to develop the micro-features. EMM process is capable of fabricating micron-size features without changing any surface property at a low cost.