4.7 Article

A sustainable, high-quality method for machining film cooling holes: Cryogenic airflow-assisted electrochemical discharge drilling

Related references

Note: Only part of the references are listed.
Article Green & Sustainable Science & Technology

Investigation on a sustainable composite method of glass microstructures fabrication-Electrochemical discharge milling and grinding (ECDM-G)

Tianbo Wang et al.

Summary: This paper proposes a novel composite machining method of electrochemical discharge milling and grinding (ECDM-G) for glass structures with microchannel morphology. Compared with traditional electrochemical discharge machining, lower discharge energy and KH2PO4 solution as electrolyte are used, realizing energy-saving and green machining. Compared with mechanical grinding, tool wear is reduced and the sustainability of machining is improved. Theoretical simulation and experimental verification demonstrate the high machining quality and stability of ECDM-G method for glass microstructures.

JOURNAL OF CLEANER PRODUCTION (2023)

Article Automation & Control Systems

Observation and simulation investigation for the crater formation under discharge plasma movement in RT-WEDM

Xue-Cheng Xi et al.

Summary: This study investigates the discharge plasma motion in reciprocated traveling wire electrical discharge machining (RT-WEDM) by observing the discharge gap. It is found that the discharge plasma continuously slides on the workpiece surface. An oscillating moving heat source is proposed to describe the characteristics of discharge plasma motions. A novel thermal-fluid coupling model is developed to investigate the crater formation and the effects of machining parameters on craters. The proposed model considers the discharge plasma sliding, latent heat, and molten pool forces.

INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY (2023)

Article Electrochemistry

Morphological evolution and anodic electrochemical behaviors of Ni-based single crystal superalloy and its recast layer in NaNO3 electrolyte

Tianyu Geng et al.

Summary: Ni-based single crystal superalloy is widely used in turbine blades, which require film cooling holes with high machining efficiency. This paper investigates the anodic electrochemical behavior of a Ni-based single crystal superalloy and its recast layer in NaNO3 electrolyte, and elucidates the surface morphology change of electrochemical dissolution. The results show that the recast layer after EDM has a stronger corrosion resistance than the matrix due to elevated oxide content within the passivation film.

ELECTROCHIMICA ACTA (2023)

Article Engineering, Aerospace

3D multiphysic simulations of energy field and material process in radial ultrasonic rolling electrochemical micromachining

Minghuan Wang et al.

Summary: This paper studies the radial ultrasonic rolling electrochemical micromachining (RUR-EMM) technique. The authors investigate key issues in the machining process, such as electrolyte flow, gas bubble removal, and the effect of vibration on electrolyte temperature, through the establishment of a multiphysics coupling model and three-dimensional multiphysics simulation. Verification experiments demonstrate the advantages of RUR-EMM technology in micro dimple machining.

CHINESE JOURNAL OF AERONAUTICS (2022)

Article Materials Science, Multidisciplinary

Insight into the passivation and corrosion behavior of additive manufacturing repaired single crystal superalloy

Xiaowei Lei et al.

Summary: The passivation and corrosion behaviors of additive manufacturing repaired Ni-based single crystal superalloy were analyzed, revealing that the cladding layer has a thicker passive film providing better protection, while the interdendritic zones are more susceptible to corrosion.

CORROSION SCIENCE (2022)

Article Engineering, Manufacturing

Electrolytic-dielectrics: A route to zero recast electrical discharge machining

Shamraze Ahmed et al.

Summary: Electrical discharge machining (EDM) is a widely used manufacturing process for machining hard or high melting point metals. Previous attempts to remove the defective recast layer have increased process complexity, and existing EDM ECM hybrid processes have failed to understand the process mechanisms and propose methods to control removal mechanisms. This study introduces tailored electrolytic-dielectrics to eliminate the defective recast layer while maintaining machining rate.

INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE (2022)

Article Materials Science, Multidisciplinary

Custom-designed heat treatment simultaneously resolves multiple challenges facing 3D-printed single-crystal superalloys

Sicong Lin et al.

Summary: Single-crystal Ni-based superalloys are the preferred materials for turbine blade applications, and additive manufacturing (AM) has facilitated their manufacture/repair. However, the traditional super-solvus solutionizing annealing causes recrystallization and stray grain growth, degrading the high-temperature mechanical performance. We propose a custom-designed post-printing heat treatment that achieves chemical homogenization while limiting grain coarsening. This strategy effectively resolves the challenges in additive manufacturing of single-crystal superalloys.

MATERIALS & DESIGN (2022)

Article Engineering, Industrial

An electrochemical discharge drilling method utilising a compound flow field of different fluids

Chenxiang Zhang et al.

Summary: DF-ECDD is a compound machining method that combines electrical discharge machining (EDM) and electrochemical machining (ECM) simultaneously, reducing the stray electric field distribution on the workpiece surface. The conductivity of the external flushing liquid affects the stray current and stray corrosion areas on the workpiece surface, leading to the elimination of stray corrosion with the DF-ECDD process.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2021)

Article Engineering, Industrial

Surface formation mechanism in waterjet guided laser cutting of a Ni-based superalloy

Zhirong Liao et al.

Summary: Waterjet guided laser (WJGL) cutting is a relatively new technology for high-precision machining of difficult-to-cut materials. This paper investigates the surface formation mechanism in WJGL cutting of Ni-based superalloy and its influence on the fatigue performance. Unique microstructures on the surface layer and mechanical twinning structures in the substrate have been revealed in the study.

CIRP ANNALS-MANUFACTURING TECHNOLOGY (2021)

Article Engineering, Mechanical

A Lattice-misfit-dependent Micromechanical Approach in Ni-based Single Crystal Superalloys

Jean-Briac Le Graverend et al.

Summary: The study investigates the impact of lattice misfit and microstructural states on the macro-scale performance of Ni-based single crystal superalloys. A micromechanical model was developed that incorporates lattice-misfit-dependent isotropic hardening for different phases. Finite-element simulations of strain-controlled monotonic tensile and cyclic tests on realistic 3D phase-field microstructures revealed that larger natural lattice misfits lead to smaller macroscopic yield stress and strain hardening. Additionally, a more pronounced rafted microstructure results in decreased stress triaxiality at the microscale.

INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES (2021)

Article Materials Science, Coatings & Films

Oxidation behavior of recast layer of air-film hole machined by EDM technology of Ni-based single crystal blade and its effect on creep strength

Haiqing Pei et al.

Summary: Investigation of the high temperature oxidation behavior of the recast layer on a Ni-based single crystal turbine blade revealed significant loss of Al element, hindering the formation of protective oxide and accelerating oxidation rate. The uneven distribution of solute elements in the recast layer leads to varying speeds of reaction with oxygen. Oxidation of the recast layer greatly promotes creep fracture.

SURFACE & COATINGS TECHNOLOGY (2021)

Article Materials Science, Multidisciplinary

Effect of crystallographic orientation on the corrosion resistance of Ni-based single crystal superalloys

Yanqiu Yang et al.

CORROSION SCIENCE (2020)

Article Engineering, Industrial

Electrolyte jet machining of Ti1023 titanium alloy using NaCl ethylene glycol-based electrolyte

Weidong Liu et al.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2020)

Article Engineering, Manufacturing

Surface integrity of holes machined by electrochemical discharge drilling method

Chenxiang Zhang et al.

CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY (2020)

Review Engineering, Manufacturing

Multiphysics study in air-shielding electrochemical micromachining

M. H. Wang et al.

JOURNAL OF MANUFACTURING PROCESSES (2019)

Article Engineering, Manufacturing

Eliminating spikes by optimizing machining parameters in electrochemical drilling

Yuhang Zhang et al.

JOURNAL OF MANUFACTURING PROCESSES (2019)

Article Chemistry, Applied

Electrochemical oxidation of ethylene glycol in a channel flow reactor

N. L. Chauhan et al.

CATALYSIS TODAY (2018)

Article Engineering, Mechanical

Prediction method for creep life of thin-wall specimen with film cooling holes in Ni-based single-crystal superalloy

ZhiXun Wen et al.

INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES (2018)

Article Chemistry, Physical

Formation of metastable cellular microstructures in selective laser melted alloys

K. G. Prashanth et al.

JOURNAL OF ALLOYS AND COMPOUNDS (2017)

Article Physics, Applied

A novel thermo-hydraulic coupling model to investigate the crater formation in electrical discharge machining

Jiajing Tang et al.

JOURNAL OF PHYSICS D-APPLIED PHYSICS (2017)

Article Materials Science, Multidisciplinary

Analysis of surface quality of multi-film cooling holes in nickel-based single crystal superalloy

Z. Wen et al.

MATERIALS SCIENCE AND TECHNOLOGY (2016)

Proceedings Paper Electrochemistry

EDM Drilling and Shaping of Cooling Holes in Inconel 718 Turbine Blades

M. Kliuev et al.

18TH CIRP CONFERENCE ON ELECTRO PHYSICAL AND CHEMICAL MACHINING (ISEM XVIII) (2016)

Article Engineering, Manufacturing

Tube electrode high-speed electrochemical discharge drilling using low-conductivity salt solution

Yan Zhang et al.

INTERNATIONAL JOURNAL OF MACHINE TOOLS & MANUFACTURE (2015)

Article Engineering, Industrial

Effects of pulsating electrolyte flow in electrochemical machining

Xiaolong Fang et al.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2014)

Article Materials Science, Multidisciplinary

A new high-strength and corrosion-resistant Al-Si based casting alloy

Z. X. Liang et al.

MATERIALS LETTERS (2013)

Article Materials Science, Multidisciplinary

Selective dissolution of the γ phase in a binary Ni(γ)/Ni3Al(γ′) two-phase alloy

Hye-Youn Lee et al.

CORROSION SCIENCE (2010)

Article Engineering, Industrial

Shaped tube electrochemical drilling of good quality holes

S. Ali et al.

CIRP ANNALS-MANUFACTURING TECHNOLOGY (2009)

Article Engineering, Industrial

Abrasive micro-blasting to improve surface integrity of electrical discharge machined WC-Co composite

J Qu et al.

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY (2005)

Review Thermodynamics

A review of shaped hole turbine film-cooling technology

RS Bunker

JOURNAL OF HEAT TRANSFER-TRANSACTIONS OF THE ASME (2005)

Article Engineering, Manufacturing

Improving electrical discharge machined surfaces using magnetic abrasive finishing

BH Yan et al.

MACHINING SCIENCE AND TECHNOLOGY (2004)

Article Electrochemistry

Microscopic investigations of electrochemical machining of Fe in NaNO3

MM Lohrengel et al.

ELECTROCHIMICA ACTA (2003)