The increasing demand for optimised component surfaces with enhanced chemical and geometric complexity is a key driver in the manufacturing technology required advanced surface production. Current methodologies cannot create complex an efficient scalable manner robust engineering materials. Hence, there need technologies which overcome this. are limited by resolution, flexibility mode of energy delivery. By addressing fundamental limitations electrochemical jetting techniques through...

The formation of passivating layers in some materials inhibits their machinability via electrochemical processes. These, relatively inert coatings, prevent direct attack by the incident electrolyte. This is particularly problematic Electrolyte Jet methods. In this study use ultrasonics explored for purpose assisting removing layer during machining Experiments presented here show that scale which forms can be partially removed as a result ultrasonic assistance thus enhancing overall...

Electrochemical jet processing techniques have traditionally been considered to be limited planar interactions with the electrolyte being maintained normal workpiece surface. In this study, viability and resultant effects of articulating nozzle relative work were investigated for first time. Two machining conventions defined, normal, where is perpendicular traverse direction, push/pull, rotated respect direction travel. It was found, convention that a range differing profile surface...

Electrolyte Jet Machining (EJM) is a non-contact machining process whereby material removed through highly localised electrochemical dissolution. Throughout the development of this technique, difficulties have been reported in processing titanium alloys due to formation an electrochemically inert non-conductive passivating layer. In study, various electrolytes are investigated for purpose establishing more stable and controlled removal Surface finish, rate pit formations using solutions...

This paper investigates the use of Electrochemical Jet Machining to surface texture a hyper-eutectic Al-Si cylinder liner material. Samples were lapped 6 μm finish followed by immersion in 1 mol NaOH expose primary silicon colonies above aluminium surface. Texturing was carried out using NC system comprising fine gauge nozzle (cathode) jetting solution 2.3 NaCl on (anode) whilst applying current density 220 A/cm2. An array hemispherical dimples at 1.5 mm spacing created, with an average...

Electrochemical jet processing techniques provide an efficient method for large area surface structuring and micro-milling, where the metallurgy of near-surface is assured not adversely affected by thermal loading. Here, doped electrolytes are specifically developed to exploit Gaussian energy distribution as found in beam processes. This allows up 26% reduction dissolution kerf enhancements defined precision metric 284% when compared standard electrolytes. achieved through filtering low at...

Orientation affects application-defining properties of crystalline materials. Hence, information in this regard is highly-prized. We show that electrochemical jet processing (EJP), when coupled with accurate metrological appraisal, can characterise crystallographic texture. Implementation technique allows localised dissolution to be anisotropic and dependent on etch-rate selectivity, defined by the crystallography. EJP therefore, generates complex, but characteristic topographies. Through...

Traditional methods for achieving hierarchical surface structures include highly specified, deterministic approaches to create features meet design intention. In this study microstructural alteration was undertaken using laser apparatus and secondary texturing achieved via succeeding electrochemical processes. Electrochemical jet machining (EJM) performed on mild steel subjected pre-treatment power densities of 4167 5556 W/cm2 with pulse durations from 0.3–1.5 s. Results show that in...

Component surface optimisation through the application of structuring is understood to be beneficial performance and longevity a component in service. However, multi-functional requirements defined at design stage can difficult realise. Utilisation electrochemical jet processing (EJP) methods allows wide-range variation structures over multitude length scales. Surface characteristics such as roughness depth cut controlled by selection suitable process parameters. With an optimised control...

Surface preparation for advanced materials inspection methods like electron backscatter diffraction (EBSD) generally involve laborious and destructive material sectioning sequential polishing steps, as EBSD is sensitive to both sample topography microstrain within the near-surface. While new methodologies, focussed ion beam femtosecond laser milling are capable of removing in a layer-by-layer manner enable construction tomographic datasets microscope, such techniques incur high initial...

Electrochemical jet machining (EJM) is a non-conventional process whereby material removed by jet-based anodic dissolution phenomena. As process, EJM capable of selectively texturing conductive materials, however there are aspects the technique that have been subject to only limited study. The effect precondition on resulting surface texture studied here for polycrystalline copper sheet (C101), and influence increasing grain size plastic deformation surfaces explored. after shown be...

Remarkable interfacial behaviors are observed in nature. Our efforts, directed toward replicating the structures, chemistries, and therefore functional properties of natural nonwetting surfaces, competing with result billions years selection. The application man-made surfaces is challenged by their poor longevity aggressive environmental or applied service conditions. This study reports on a new approach for creation multiscale hierarchical surface patterns metals, which exploits...

Electrolyte design for electrochemical jet processing (EJP) techniques can directly affect form and finish of machined structures. A newly developed, industrially focused, EJP machining centre was designed to incorporate complete control all relevant parameters. computer numerically controlled, electrolyte multiplexing system, developed allow rapid changes in type the ability mix fade between electrolytes create roughing finishing strategies, functionally graded surfaces as part toolpath...

In this study, we describe a new methodology to create complex coatings with functionally graded compositions, using electrochemical jet processing (EJP). Cu/Zn alloy were electrodeposited, in layer-by-layer manner, onto steel substrates through resin masks created desktop 3D printer. By adapting the electrolyte composition by drawing from multiple reservoirs, ratio of cations (Cu2+:Zn2+) supplied directly substrate surface at any point cycle can be manipulated. This allows for control over...