Influence of Silver-Coated Tool Electrode on Electrochemical Micromachining of Incoloy 825

Abstract

Incoloy 825 alloy is often used in calorifiers, propeller shafts, and tank vehicles owing to the improved resistance to aqueous corrosion. The electrochemical micromachining process can be utilized to machine such an engineering material owing to higher precision and lower tool wear. In the present study, an investigation was performed to enhance the process of creating micro-holes using silver-coated copper tool electrodes. The sodium nitrate electrolyte was used under different levels of input parameters such as voltage, electrolyte concentration, frequency, and duty cycle with a view to improving material removal rate, conicity, overcut, and circularity. It was found that silver-coated copper tool electrode had a high material removal rate (MRR), better overcut, conicity, and circularity compared to uncoated copper tools in most cases, due to its high corrosive resistance and electrical conductivity. From SEM and EDS analysis, it was observed that better surface topography of the micro-holes is obtained with silver-coated copper tool electrode while machining Incoloy 825 alloy in the micromachining process.

Influence of Cryogenic Coated Copper Tool Electrode in Electrochemical Micro Machining process of Stainless Steel 316

“…The experiments ECMM processes were conducted with process parameters such as voltage supplied, concentration of electrolyte, feed rate and duty cycle on MRR, roughness (Ra) for various parameter levels using two different electrolytes. The formation of sludge error occurs on repeated occasions and thus memory errors seem to occur and addressing of wastage and accuracy improvement is the only answer [7]. The experiment has to be verified the predicted results using an ECM system.…”