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Self-induced electrical discharge machining of Ni–Al2O3 functionally graded materials

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Abstract

Ni–Al2O3 functionally graded materials (FGMs) have become important for high-temperature applications due to a continuous change in composition. However, the manufacturing of Ni–Al2O3 FGMs with conventional machining methods is a long and costly process because of the insulating ceramic composition. This paper presents a new method of machining Ni–Al2O3 FGMs by self-induced electrical discharge machining (EDM). Self-induced EDM uses the conductive compositions of Ni–Al2O3 FGMs to trigger the discharges in the insulating composition. Machining characteristics of a four-layered Ni–Al2O3 FGMs drilled by self-induced EDM have been investigated, which include the material removal mechanisms, discharge properties, surface characteristics, material removal rate, and electrode wear ratio. It has been found that graded layers, 70 % Ni-graded layer and 30 % Ni-graded layer, are removed by dislodgement of Al2O3 particles, in addition to conventional melting and evaporation. Pure Al2O3 layer is melted and evaporated by utilizing conductive layer-induced discharges. The discharge properties, surface characteristics, material removal rate, and electrode wear ratio are significantly influenced by the material removal mechanisms of graded compositions. These findings demonstrate that self-induced EDM is able to effectively machine Ni–Al2O3 FGMs.

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Authors and Affiliations

  1. Key Laboratory of Micro-systems and Micro-structures Manufacturing of Ministry of Education, Harbin Institute of Technology, Harbin, 150001, People’s Republic of China

    Hongzheng Liu, Zhenlong Wang & Yukui Wang

  2. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, People’s Republic of China

    Hongzheng Liu, Zhenlong Wang, Yukui Wang & Huichao Li

Authors
  1. Hongzheng Liu
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  2. Zhenlong Wang
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  3. Yukui Wang
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  4. Huichao Li
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Correspondence to Zhenlong Wang.

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Liu, H., Wang, Z., Wang, Y. et al. Self-induced electrical discharge machining of Ni–Al2O3 functionally graded materials. Int J Adv Manuf Technol 83, 587–594 (2016). https://doi.org/10.1007/s00170-015-7568-2

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  • DOI: https://doi.org/10.1007/s00170-015-7568-2

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