Insights on the Influence of Surface Chemistry and Rim Zone Microstructure of 42CrMo4 on the Efficiency of ECM

The electrochemical machining (ECM) of 42CrMo4 steel in sodium nitrate solution is mechanistically characterized by transpassive material dissolution and the formation of a Fe3−xO4 mixed oxide at the surface. It is assumed that the efficiency of material removal during ECM depends on the structure and composition of this oxide layer as well as on the microstructure of the material. Therefore, 42CrMo4 in different microstructures (ferritic–pearlitic and martensitic) was subjected to two ECM processes with current densities of about 20 A/cm2 and 34 A/cm2, respectively. The composition of the process electrolyte was analyzed via mass spectrometry with inductively coupled plasma in order to obtain information on the efficiency of material removal and the reaction mechanisms. This was followed by an X-ray photoelectron spectroscopy analysis to detect the chemical composition and the binding states of chemical elements in the oxide formed during ECM. In summary, it has been demonstrated that the efficiency of material removal in both ECM processes is about 5–10% higher for martensitic 42CrMo4 than for ferritic–pearlitic 42CrMo4. This is on one hand attributed to the presence of the cementite phase at ferritic–pearlitic 42CrMo4, which promotes oxygen evolution and therefore has a negative effect on the material removal efficiency. On the other hand, it is assumed that an increasing proportion of Fe2O3 in the mixed oxide leads to an increase in the process efficiency.

Oxide Formation during Transpassive Material Removal of Martensitic 42CrMo4 Steel by Electrochemical Machining

The efficiency of material removal by electrochemical machining (ECM) and rim zone modifications is highly dependent on material composition, the chemical surface condition at the break through potential, the electrolyte, the machining parameters and the resulting current densities and local current density distribution at the surfaces. The ECM process is mechanistically determined by transpassive anodic metal dissolution and layer formation at high voltages and specific electrolytic compositions. The mechanisms of transpassive anodic metal dissolution and oxide formation are not fully understood yet for steels such as 42CrMo4. Therefore, martensitic 42CrMo4 was subjected to ECM in sodium nitrate solution with two different current densities and compared to the native oxide of ground 42CrMo4. The material removal rate as well as anodic dissolution and transpassive oxide formation were investigated by mass spectroscopic analysis (ICP-MS) and (angle-resolved) X-ray photoelectron spectroscopy ((AR)XPS) after ECM. The results revealed the formation of a Fe3−xO4 mixed oxide and a change of the oxidation state for iron, chromium and molybdenum, e.g., 25% Fe (II) was present in the oxide at 20.6 A/cm2 and was substituted by Fe (III) at 34.0 A/cm2 to an amount of 10% Fe (II). Furthermore, ECM processing of 42CrMo4 in sodium nitrate solution was strongly determined by a stationary process with two parallel running steps: 1. Transpassive Fe3−xO4 mixed oxide formation/repassivation; as well as 2. dissolution of the transpassive oxide at the metal surface.

Wire Electrochemical Micromachining of Aluminum Rings for the Fabrication of Short-Millimeter Corrugated Horns

With the increase of working frequency, the feature size of a corrugated horn will be greatly reduced, causing challenges for fabrication. This paper investigated wire electrochemical micromachining (WECMM) of aluminum rings for assembly of a mandrel for electroforming, which has been a primary method for producing corrugated horns. By utilizing a rotary helical electrode and green additives, the removal efficiency of electrolytic products in WECMM was improved. It was found that the machined slits had good unilateral consistency on the left side of the electrode feeding direction when the electrode rotated clockwise. Complexing agent glutamic diacetic acid (GLDA) can compete with OH− for Al3+ and has an obvious effect in reducing insoluble electrolytic products. From experimental investigations on typical parameters, an optimal parameter combination considering slit homogeneity and machining efficiency was obtained. In an electrolyte solution containing 15 g/L sodium nitrate solution and 15 g/L GLDA, 100 μm-thick aluminum rings with good edge and surface qualities were fabricated at a rate of 1.2 μm/s using a helical electrode with a diameter of 0.3 mm. Finally, these aluminum rings were successfully applied to make an internal corrugated sample with a rib width of 100 μm and a groove depth of 500 μm.

Modeling and Numerical Analysis of Advanced Machining for Orthotic Components

Electrochemical micromachining plays a vital role in the advanced machining domain. Particularly, it helps the medical industry in machining micro-level devices in hardened materials. Though it is maintaining a very small inter-electrode gap during machining, it is required to understand suitable machining parameters before machining. These parameters can be achieved by proper modeling and simulation. In this chapter, a model for flow analysis of electrolytes in inter-electrode gaps is designed to obtain optimal process parameters for machining. The geometric model used in this simulation consists of cylindrical workpiece, an inlet allowing the flow of sodium nitrate solution as electrolyte to the machining zone, and a cylindrical tool with a flat end. Electrolytic flow simulation is incorporated using computational fluid dynamics by ANSYS–CFX 15.0 for finding pressure variation, streamline velocity pattern, turbulent energy, and temperature contour in IEG. According to the CFD analysis, the passivation effect, stagnation effect, pressure, and temperature zone are studied.

Evaluation of Parasite Egg and Cyst Recovery Using Devices Designed for Centrifugal or Stationary Flotation

ABSTRACT Two new devices (OT, ST), were recently introduced for the recovery of parasite eggs and cysts for microscopic examination. These devices, two stationary flotation devices, and a standard double-centrifugal sugar-flotation were compared using common flotation solutions and methods recommended by the manufacturers for the recovery of hookworm, ascaridoid, and whipworm eggs from companion animal fecal samples. Additionally, the recovery of Giardia cysts in the OT device using a zinc sulfate versus sodium nitrate solution was evaluated. Double-centrifugal sugar-flotation (1.30 specific gravity) was the most sensitive method for the recovery of the nematode eggs from feces of companion animals. Overall, centrifugation increased the recovery of eggs as compared with standing flotation methods, with the ST performing equivalently to the OT. Although these more recently introduced tests have good sensitivities for the nematodes tested, egg recovery was routinely markedly less than that achieved by standard double-centrifugal sugar-flotation, and false-negatives did occur. Still, the OT and ST generally have increased recoveries over the two standing flotation devices, and are significantly better than these for the recovery of ascaridoid and whipworm eggs from dog and cat samples. Zinc sulfate (1.18 specific gravity) is recommended for the recovery of Giardia cysts when using the OT device.

Pitting resistivity of Ni-based bulk metallic glasses in chloride solution

Resistance of new Ni70Cr21Si0.5B0.5P8C≤0.1Co≤1Fe≤1 and Ni72.65Cr7.3Si6.7B2.15C≤0.06Fe8.2Mo3 glassy alloys to pitting corrosion was studied in 0.25 M sodium nitrate solution, with or without addition of chloride ions, using EIS, CP and EFM techniques.