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Electrochemical micromachining of shape memory alloy: effect of polymer composite electrodes on micro-hole surface integrity
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DOI：10.1007/s10800-026-02477-4.png)
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Abstract
En 中文
The application of micro-holes in critical components is increased new ages in many medical, electronic and biotechnology devices. Electrochemical micromachining (ECMM) is widely used for fabricating these micro-holes. However, the process often leads to excessive overcut. Therefore, minimizing overcut while maximizing the machining rate is critical and both are significantly influenced by the electrode material, coatings and tool electrode treatment. This research explores novel electrode materials, coatings and treatments to identify suitable tool electrode. Specifically electrodes such as, Copper mixed epoxy polymer composite (EPCE), nickel-coated copper (NICE), heat-treated copper (HTCE) and Normal stainless steel (NRSE) electrodes were investigated. The study examined the effects of electrolyte concentration (g/L), machining voltage (V) and duty cycle (%) on overcut and machining rate along different tool electrodes. Compared to NRSE, EPCE produced the least overcut (28.1 mu m) with parameter combination of 22 g L- 1, 16 V, and 90%, while HTCE produced the second least overcut (42.23 mu m) with parameter combination of 60%, 15 V and 31 g L- 1. The NICE and HTCE produces the first two highest machining rates 78.9% and 61.23% respectively than NRSE with the parameter combination of 22 g/l, 16 V, and 90%. Scanning electron microscope (SEM) images of the micro-holes provided visual evidence of the effects of tool material and coating on the micro holes circumference. [GRAPHICS]
Keywords:
Shape Memory alloy
Epoxy
Heat treatment
Nickel
Coating
Electrode
Overcut
Machining rate
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