Pulsed Unipolar-Polarisation Plasma Electrolytic Polishing of Ni-Based Superalloys: A Proof of Conception

• Published in: Chinese journal of mechanical engineering Vol. 37; no. 1; pp. 105 - 17
• Main Authors: Zhou, Chuanqiang, Qian, Ning, Su, Honghua, He, Jingyuan, Ding, Wenfeng, Xu, Jiuhua
• Format: Journal Article
• Language: English
• Published: Singapore Springer Nature Singapore 26.09.2024; Springer Nature B.V; SpringerOpen
• Edition: English ed.
• Subjects: 3-D printers; Electric discharge machining; Electric potential; Electrical Machines and Networks; Electronics and Microelectronics; Electropolishing; Engineering; Engineering Thermodynamics; Heat and Mass Transfer; Instrumentation; Intelligent Manufacturing Technology; Machines; Manufacturing; Material removal rate; Material removal rate (machining); Mechanical Engineering; Nickel base alloys; Original Article; Performance enhancement; Plasma electrolytic polishing; Polarization; Power Electronics; Processes; Pulsed unipolar-polarisation; Superalloy; Superalloys; Surface finishing; Surface roughness; Theoretical and Applied Mechanics; Three dimensional printing; Voltage; Voltage waveform; Waveforms; Workpieces; Pulsed unipolar-polarisation; Plasma electrolytic polishing; Superalloy; Surface roughness; Material removal rate; Voltage waveform
• ISSN: 2192-8258; 1000-9345; 2192-8258
• DOI: 10.1186/s10033-024-01085-7

The enhanced performance of aerospace equipment drives parts development towards integration, complexity, and structural optimization. This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining (WEDM) and 3D printing. However, the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required. To effectively reduce the surface roughness of the workpieces with high initial surface roughness, this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing (PUP-PEP). The study examined the material removal mechanisms and surface polishing quality of PUP-PEP. This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation. For an Inconel-718 superalloy part fabricated by WEDM, PUP-PEP reduced surface roughness from R a 7.39 μm to R a 0.27 μm in 6 min under optimal conditions. The roughness decreased from R a 7.39 μm to R a 0.78 μm in the first 3 min under pulsed unipolar-polarisation voltage, resulting in a remarkable 233% increase in efficiency compared to that with conventional PEP. Subsequently, the voltage output voltage is transformed into a constant voltage mode, and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to R a 0.27 μm. The proposed PUP-PEP technology marks the implementation of ‘polishing’ instead of conventional rough-finish machining processes, presenting a new approach to the surface post-processing of metal near-net fabrication technologies.