A hybrid short electric arc and electrochemical machining of the Ti6Al4V alloy

In this study, the persistent challenges of high surface roughness and large thickness of the re-solidified layer (RSL) and the heat-affected zones (HAZ) in short electric arc machining (SEAM) are confronted by a hybrid simultaneous SEAM and ECM (SEACM) technique. The SEACM is investigated in low conductivity NaCl electrolytes as the working medium with an additionally applied air pressure, which can meet the requirements of both SEAM and ECM. Firstly, the effect of feed rate and electrolyte conductivities on material removal rate (MRR), roughness, line profiles, and surface morphologies were studied. Later, the current-voltage waveforms, topographies, PSD curves, and dimensional accuracy at different feed rates and electrolyte conductivities were analyzed. The SEACM significantly reduced the roughness and the thickness of RSL and HAZ at an appropriately optimized electrolyte conductivity and feed rate. The developed technique provides the basis for transferring from rough machining to finishing in SEAM.