Investigation of stable boundary conditions for the Jet-electrolytic Plasma Polishing (Jet-ePP)

Kranhold, Christian; Kröning, Oliver; Schulze, H.‐P.; Herzig, Mathias; Zeidler, Henning

doi:10.1016/j.procir.2020.02.294

Cited by 9 publications

(4 citation statements)

References 1 publication

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“…This is considered ascribed to a more developed gas layer on the anode surface, which reduces the discharge energy and improves the local evenness of discharge distribution. That is, the higher electrolyte temperature facilitates warm gas formation by Joule heating, 14 thereby leading to a more significant gas layer formation. As can be seen in Fig.…”

Section: Resultsmentioning

confidence: 99%

“…When implementing an electrified jet on a passivating metal like Nb, a high-resistance oxide layer is readily formed anodically on the workpiece surface, preventing the electrochemical dissolution of the substrate material. Meanwhile, cold gas formation by anodic oxygen evolution occurs on the workpiece surface, 14,15 consuming a large portion of the applied current. In addition, warm gas formation by Joule heating may take place.…”

Section: Methodsmentioning

confidence: 99%

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Enabling Jet-Electrochemical Discharge Machining on Niobium-Like Passivating Metal and the Single Step Fabrication of Coated Microstructures

Lu,

Liu,

Zhao

2023

J. Electrochem. Soc.

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Analogous to difficult-to-cut materials in mechanical machining, Niobium (Nb) is a difficult-to-dissolve metal by electrochemical machining (ECM) due to its prone-to-passivation nature. Jet-electrochemical discharge machining (Jet-ECDM), which uses anodic discharge rather than the cathodic discharge as in traditional ECDM, has been previously demonstrated as an efficient method for machining inert semiconductors like Si, 4H-SiC. However, applying Jet-ECDM on Nb-like passivating metal is very challenging because plasma electrolytic oxidation (PEO) is very prone to occur in the machining area due to anodic discharges, forming an insoluble, highly stable oxide coating that prevents material removal. This study reveals the principles of overcoming PEO to enable Jet-ECDM on metals. The findings show that the discharge intensity, affected by the electric field and pulse frequency, is decisive in achieving Nb material removal. The electrolyte chemistry significantly influences material removal fashions, depending on the electrolyte's chemical activity. NaOH is the preferred choice for higher removal efficiency (maximum 1.92 mm/min) and machining localization, while NaCl ensures better surface quality (Sa 99.4 nm). Moreover, the Jet-ECDM generated microstructure surface presents a thin layer of PEO coatings (<1 μm). This demonstrates the high potential of Jet-ECDM technology for efficient fabrication of coated microstructures in a single-step process.

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Section: Resultsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Enabling Jet-Electrochemical Discharge Machining on Niobium-Like Passivating Metal and the Single Step Fabrication of Coated Microstructures

Lu,

Liu,

Zhao

2023

J. Electrochem. Soc.

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“…The high potentials promote electrode reactions, including electrolytic gas evolution and anodic oxidation. In addition, warm gas formation by Joule heating probably takes place simultaneously [22]. As a result, a surface boundary layer consisting of a high-resistance oxide film and an insulating vapor gaseous film forms at the jet-impinging area on the surface of the workpiece.…”

Section: Concept and Process Principle Of Jet-epmmentioning

confidence: 99%

“…Clare et al showed the adaptation of electrochemical jet processing to create a PEO surface for hard coating of microfeatures (≈500 µm width) on titanium alloy for surface enhancement in thermal and mechanical properties [21]. Kranhold et al performed a study on the jet-electrolytic plasma polishing process and demonstrated the influence of changing boundary conditions and jet parameters on the process characteristics [22]. In contrast, there is little research on the realization of micromachining an inert material by jet-electrolytic plasma.…”

Section: Introductionmentioning

confidence: 99%

Plasma-enabled electrochemical jet micromachining of chemically inert and passivating material

Zhan

Liu

et al. 2022

Int. J. Extrem. Manuf.

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Electrochemical jet machining (EJM) encounters significant challenges in the microstructuring of chemically inert and passivating materials because an oxide layer is easily formed on the material surface, preventing the progress of electrochemical dissolution. This research demonstrates for the first time a jet-electrolytic plasma micromachining (Jet-EPM) method to overcome this problem. Specifically, an electrolytic plasma is intentionally induced at the jet-material contact area by applying a potential high enough to surmount the surface boundary layer (such as a passive film or gas bubble) and enable material removal. Compared to traditional EJM, introducing plasma in the electrochemical jet system leads to considerable differences in machining performance due to the inclusion of plasma reactions. In this work, the implementation of Jet-EPM for fabricating microstructures in the semiconductor material 4H-SiC is demonstrated, and the machining principle and characteristics of Jet-EPM, including critical parameters and process windows, are comprehensively investigated. Theoretical modeling and experiments have elucidated the mechanisms of plasma ignition/evolution and the corresponding material removal, showing the strong potential of Jet-EPM for micromachining chemically resistant materials. The present study considerably augments the range of materials available for processing by the electrochemical jet technique.

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Local surface smoothness on TC4 alloy during microbubbles flow electrolytic plasma polishing: prototype rig, phenomena, and mechanism

Wang,

Sun,

Yang

et al. 2024

Int J Adv Manuf Technol

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Investigation of stable boundary conditions for the Jet-electrolytic Plasma Polishing (Jet-ePP)

Cited by 9 publications

References 1 publication

Enabling Jet-Electrochemical Discharge Machining on Niobium-Like Passivating Metal and the Single Step Fabrication of Coated Microstructures

Enabling Jet-Electrochemical Discharge Machining on Niobium-Like Passivating Metal and the Single Step Fabrication of Coated Microstructures

Plasma-enabled electrochemical jet micromachining of chemically inert and passivating material

Local surface smoothness on TC4 alloy during microbubbles flow electrolytic plasma polishing: prototype rig, phenomena, and mechanism

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