Electrochemical Micromachining of Hastelloy C276 by Different Electrolyte Solutions
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RESEARCH ARTICLE-MECHANICAL ENGINEERING
Electrochemical Micromachining of Hastelloy C276 by Different Electrolyte Solutions Gowtham Kumarasamy1 · Poovazhagan Lakshmanan1
· Geethapriyan Thangamani2
Received: 6 March 2020 / Accepted: 9 June 2020 © King Fahd University of Petroleum & Minerals 2020
Abstract Micro-electrochemical machining (µECM) is a non-traditional material removal technique developed to cut incredibly hard surfaces which are not easy to cut by any traditional methods. Hastelloy C276 is a nickel-based superalloy, and its applications include equipment components of chemical processing units, food processing units and pharmaceutical industries. Due to the work hardening tendency, machining of Hastelloy C276 by conventional manner becomes exceedingly difficult. µECM can be a possible alternative fabrication technology for machining Hastelloy C276 particularly in micro-domain. This work demonstrates the µECM (micro-hole making) behavior of Hastelloy C276 using NaCl, NaNO3 and hybrid mixture (NaCl + NaNO3 + citric acid) as electrolyte solutions. L9 statistical design of experiments was employed to reduce the number of experiment trials required. Taguchi grey relational approach was executed to determine the most favorable machining variables. Confirmation tests were performed, and the error percentage was calculated. Surface irregularities of the machined parts were systematically examined by 3D surface roughness tester. Experimental results revealed that all the output performances are highly dependent on the type of electrolyte used. Hybrid electrolytic combination produced better material removal rate, lower overcut, lower conicity and most circular holes. Scanning electron microscopy images were used to identify the best-, moderate- and poor-quality micro-holes. Keywords Micro-electrochemical machining · Hastelloy C276 · Electrolytes · Material removal rate · Taguchi · Scanning electron microscopy
1 Introduction Due to the extraordinary anti-corrosive properties, Hastelloy (Ni-based superalloy) is extensively used in chemical processing units, energy, petrochemical, environmental pollution & control and desulfurization industries [1]. Machining of Ni and its alloys becomes more difficult because of its exceptional strength and below normal heat conductivity at elevated temperature [2–5]. Machining of Ni alloys at a speed of 300 m/min produces high working temperature in the order of 1000 °C [6, 7]. Due to product miniaturization and development of new materials with extreme properties, there is a need for advanced machining technologies [8].
B
Poovazhagan Lakshmanan [email protected]
1
Sri Sivasubramaniya Nadar (SSN) College of Engineering, Chennai, India
2
SRM Institute of Science and Technology, Chennai, India
Researchers are motivated by the properties of Ni-based alloys such as shape control and metallurgical constraints to do research work in micro-domain [9]. Machining of hard materials with conventional machining process leads to more uneven surfaces, larger heat influenced re
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