Electrochemical machining of burn-resistant Ti40 alloy

This study investigates the feasibility of using electrochemical machining (ECM) to produce critical aeroengine components from a new burn-resistant titanium alloy (Ti40), thereby reducing costs and improving efficiency relative to conventional mechanical machining. Through this, it is found that an aqueous mix of sodium chloride and potassium bromide provides the optimal electrolyte and that the surface quality of the Ti40 workpiece is improved by using a pulsed current of 1 kHz rather than a direct current. Furthermore, the quality of cavities produced by ECM and the overall material removal rate are determined to be dependent on a combination of operating voltage, electrolyte inlet pressure, cathode feeding rate and electrolyte concentration. By optimizing these parameters, a surface roughness of 0.371 μm has been achieved in conjunction with a specific removal rate of more than 3.1 mm3/A·min.