Surface Texturing by Electrochemical Micromachining: A Review

Kumar, Abhinav; Kumar, Manjesh; Alok, Anupam; Das, Manas

doi:10.1088/1757-899x/804/1/012011

Cited by 10 publications

(3 citation statements)

References 27 publications

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“…The unique properties of covalently bonded compounds make them highly desirable for serving as the matrix material in films. Their exceptional hardness provides the necessary foundation for achieving films with superior mechanical properties and performance characteristics [100][101][102].…”

Section: The Matrix Filmmentioning

confidence: 99%

Insight into the Mechanisms of Nitride Films with Excellent Hardness and Lubricating Performance: A Review

Wu,

Jiang,

et al. 2023

Nanomaterials

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Transition metal nitride (TMN) films with excellent hardness and lubricating performance are versatile low dimension materials, which are widely used in various fields including industries, transportation, aerospace, and so on. This paper introduces one film design strategy and provides a review of the mechanisms for strengthening and lubricating nitride films. The design strategy refers to two aspects which determine the structures, the performance, the components, and the chemical constitutions of nitride films The strengthening mechanisms of nitride films are then illuminated in detail, including the solid solution effect, the grain size effect, the secondary phase effect, the stress or stress field effect, the template effect, and the valence electron concentration effect. Five lubricating mechanisms are next summarized, including the easy-shear nature, the tribo-chemical reactions, the lubricious fluorides, the textured contact surface, and the synergistic effect. This paper aims to give a comprehensive introduction for understanding the mechanisms of strengthening and lubrication of nitride films for students and researchers, as well as to understand the current research progress in nitride films for exploring research gaps.

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Section: The Matrix Filmmentioning

confidence: 99%

Insight into the Mechanisms of Nitride Films with Excellent Hardness and Lubricating Performance: A Review

Wu,

Jiang,

et al. 2023

Nanomaterials

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“…MECT uses localized micro-electrochemical machining of an anodic surface against a patterned cathode, but the individual workpieces do not require previous masking [32] as an advantage over other electrochemical techniques, such as through-mask electrochemical micromachining (TMEMM) [33][34][35]. Despite some drawbacks of electrochemical texturing in general, such as the difficulty of controlling the technique, the complexity involved in producing the patterned cathode, and the strong dependence of the anodic dissolution on the process parameters [36], MECT has been successfully adapted to texture cylinder liners [37,38].…”

Section: Introductionmentioning

confidence: 99%

ZDDP Tribofilm Formation from a Formulated Oil on Textured Cylinder Liners

et al. 2022

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Surface texturing can improve lubrication and entrap wear debris but increases the effective roughness of the surfaces, which can induce higher contact pressures. On the one hand, this can be detrimental, but on the other hand, the increase in contact pressure could be used to activate the formation of a ZDDP tribofilm from fully-formulated lubricants. This work investigates the synergistic effect between surface texturing via Maskless Electrochemical Texturing (MECT) and ZDDP additive. The surface texture consisted of an array of annular pockets manufactured on a gray cast iron cylinder liner. These textured surfaces were evaluated by scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDX). The results indicated that surface texturing via MECT changes the chemical composition of the surfaces, by inducing a preferential dissolution of the metal matrix. Consequently, it exposed the carbon present in the material. The tribological performance was evaluated by a ring-on-cylinder-liner tribometer in reciprocating sliding under boundary lubrication conditions using both a base oil and a commercial formulated oil containing ZDDP additive. For comparison, a commercially honed liner was also tested. After the tribological tests, the surfaces were evaluated by white light interferometry and SEM/EDX. Although the textured surfaces showed higher friction, they induced more ZDDP-tribofilm formation than conventional cylinder liner finish.

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“…Micro-tool is an essential aspect of micromachining as it is used to fabricate different 1D, 2D, and 3D microstructures like micro-dimples, microchannels. 1 Hence, the fabrication of micro-tool is an important research area. In general, microelectrodes should have properties that include high thermal and electrical conductivity, high erosion resistance, and high stiffness.…”

Section: Introductionmentioning

confidence: 99%

Effect of tool rotation on the fabrication of micro-tool by electrochemical micromachining

Kumar

Yadav

Kumar

et al. 2021

Journal of Micromanufacturing

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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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Surface Texturing by Electrochemical Micromachining: A Review

Cited by 10 publications

References 27 publications

Insight into the Mechanisms of Nitride Films with Excellent Hardness and Lubricating Performance: A Review

Insight into the Mechanisms of Nitride Films with Excellent Hardness and Lubricating Performance: A Review

ZDDP Tribofilm Formation from a Formulated Oil on Textured Cylinder Liners

Effect of tool rotation on the fabrication of micro-tool by electrochemical micromachining

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