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Investigation and optimization in electrochemical arc drilling of Ni55.7Ti nickel–titanium shape memory alloy with molybdenum electrode

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Abstract

Nickel–titanium (NiTi) shape memory alloy has diverse applications, especially in areas such as the medical, aerospace, and aeronautical industries. Due to this alloy’s excellent fatigue strength, high mechanical properties even at higher temperatures, and tendency to corrosion resistance, NiTi alloy is considered difficult to machine. In the present scenario, electrochemical arc machining ECAM (hybrid of electric discharge erosion and electrochemical dissolution) is an evolving procedure for difficult to machine the materials due to constraints of existing processes. The present research aims to investigate the machinability of Ni55.7Ti alloy through electrochemical arc drilling using molybdenum electrode. Electrolyte concentration (ethanol with ethylene glycol and sodium chloride), supply voltage, and tool rotation are considered as the variable factors in order to evaluate the ECAM performance characteristics in drilling blind hole operation concerning overcut, tool wear rate, and materials removal rate. Consequently, response surface methodology is implemented for predictive modeling of various performance characteristics. Finally, multi-objective optimization through DFA has produced a set of optimal parameters to improve the productivity along with the accuracy, which is the prime requirement for the industrial applicability of the ECAM process. Results demonstrated that supply voltage is the influential key factor for improvement of machining rate. SEM photographs revealed the development of HAZ, white layer, melted droplet, craters, re-solidified material, ridge-rich surface, and voids as well as cavities around the end-boundary surfaces of a blind hole. Composition analysis through EDS indicated the oxygen content on the machined surface because electrolyte breakdown causes oxidation to take place at elevated temperatures across the machining zone. Moreover, carbide precipitation like TiC was found in the melting zone of the drilled hole which has the affinity to reduce the SMA properties in HAZ.

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Authors and Affiliations

  1. Department of Production and Industrial Engineering, National Institute of Technology, Jamshedpur, Jharkhand, 831014, India

    Nitish Kumar & Amaresh Kumar

  2. Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Odisha, 768018, India

    Sunita Sethy & Sudhansu Ranjan Das

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  1. Nitish Kumar
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Correspondence to Sudhansu Ranjan Das.

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Kumar, N., Kumar, A., Sethy, S. et al. Investigation and optimization in electrochemical arc drilling of Ni55.7Ti nickel–titanium shape memory alloy with molybdenum electrode. J Braz. Soc. Mech. Sci. Eng. 45, 448 (2023). https://doi.org/10.1007/s40430-023-04374-9

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