Electrochemical micromachining of nickel aluminum bronze

Abstract

The Nickel Aluminum Bronze (NAB) alloy is useful in components having landing gear bearings, cast valve bodies, and perforated orifice for pharmaceutical industries. Machining of the NAB alloy in the micro-domain is a great challenge because of its unique mechanical and chemical properties. NAB alloy possesses high strength, high bearing capacity, better anti-seizing property, and superior corrosion resistant capabilities. It is one of the copper (Cu)-based alloys designed for numerous engineering applications. The machining of Cu and its alloys in a conventional method produces continuous chips, which leads to irregular surfaces and higher circularity. It is due to the high ductility of Cu and its alloys. Production of miniature holes are required in many engineering components. Especially in parts made from NAB alloys like medical devices and electronic units. It has motivated the researchers to carry out experimental research on non-traditional machining methods, which are the alternate routes for micro/mesoscale machining of Cu based alloys. The majority of the non-traditional machining processes are thermal oriented and generally result in thermal defects like heat affected zone, recast layer, and tiny fractures on the machined surfaces. These quality affecting characteristics have directed the researchers to choose a non-thermal energy-based micromachining process. Electrochemical Machining (ECM) is proficient in machining of components in the micro-domain due to its enhanced precision/control, three-dimensional (3D) machining potential of complex shapes, and absence of tool wear. The electrochemical micromachining (ECMM) is useful in machining hard to machine materials like tungsten, Cu alloys, Ni alloys,Ti alloys, and stainless steel. Several researchers have analyzed the suitability of the ECMM process on the micro-drilling of different materials. It is suggested that ECMM is a good option for producing an accurate dimensional hole with a better surface finish on the machined surfaces newline newline newline