The microstructure formation of thick Zr-based amorphous alloy with anode vibration in HClO4 solution by WECMM

• Published in: International journal of advanced manufacturing technology 2021-11, Vol.117 (5-6), p.1459-1472
• Main Authors: Yusen, Hang, Yongbin, Zeng, Tao, Yang, Zhengyang, Xu, Kun, Xu, Huimin, Wang
• Format: Article
• Language: English
• Subjects: Alloys; Amorphous alloys; Amorphous materials; Anodes; CAE) and Design; Computer-Aided Engineering (CAD; Corrosion mechanisms; Defense programs; Engineering; Fluid dynamics; Fluid flow; Industrial and Production Engineering; Mass transfer; Mathematical analysis; Mechanical Engineering; Media Management; Metallic glasses; Micromachining; Optimization; Original Article; Thickness; Vibration; Workpieces
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-021-07822-9

Zr-based amorphous alloy is a kind of material with broad application prospects in aerospace, national defense, and precision device fields. The micro-structure formation of these high-performance materials presents a major difficulty. In this paper, wire electrochemical micromachining (WECMM) technology used to process a Zr-based bulk amorphous alloy with a thickness of 1 mm is presented. Solution selection and mass transfer optimization are two important factors in WECMM. The dissolution characteristics of alloys in HCl and HClO 4 solutions were analyzed, and the corrosion mechanism of Cl − and ClO 4 − on alloys was understood. The tetrahedral epoxy structure improved the localization of WECMM, reduced stray corrosion, and improved the processing accuracy. In this study, large amplitude vibrations of the anode are used to improve the quality and efficiency of the WECMM of Zr-based amorphous alloys. The flow field distribution in the gap of anode vibration under sine mode and step modes was calculated. In the sine mode, the variable speed vibration of the workpiece drove the fluid flow out of the gap rapidly in a fluctuating state. In step mode, the fluid moved at a very high velocity at the moment when the workpiece changed direction, and flowed at a low velocity under the action of inertial force at other times. Finally, using the optimized parameters, a micro-gear with an addendum circle of 2 mm was machined with Zr-based amorphous alloy at a thickness of 1 mm.