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Procedia CIRP 42 (2016) 125 – 130

18th CIRP Conference on Electro Physical and Chemical Machining (ISEM XVIII)

Electrochemical machining of high-temperature titanium alloy Ti60


Zhengyang Xua,*, Xuezhen Chena, Zesheng Zhoua, Peng Qina, Di Zhua
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing 210016, China

* Corresponding author. Tel.: +86-025-8489-6304; fax:+86-025-8489-5912. E-mail address:xuzhy@nuaa.edu.cn

Abstract

The high-temperature titanium alloy Ti60 (Ti–5.6Al–4.8Sn–2Zr–1Mo–0.35Si–0.7Nd) is often used for manufacturing critical components of
aero-engines. The use of this alloy has made it possible to increase the service temperature to up to 600 °C. However, machining such alloys by
conventional methods is difficult, often resulting in low process efficiency, high tool wear, reduced precision, and poor surface integrity.
Electrochemical machining (ECM) is an effective method to machine titanium alloys but the electrochemical dissolution behavior of titanium
alloys is different from those of other difficult-to-cut materials such as nickel alloys. This study focuses on the ECM of the high-temperature
titanium alloy Ti60. The anodic polarization curve, open circuit potential, and actual volume electrochemical equivalent–current density curve
of Ti60 are obtained. The electrochemical dissolution behavior of Ti60 is analyzed, and the composition, concentration, and temperature of the
electrolyte used for ECM are optimized. Dissolution experiments are performed at different current densities, and results show that the surface
roughness of Ti60 undergoing ECM deteriorates when the current density is small. Finally, electrochemical parameters are optimized and a
blisk sector made of Ti60, which is to be used in an aero-engine compressor, is machined by ECM. The process is stable and efficient. The
maximum machining rate of the channels is more than 1.2mm/min. The best surface roughness is Ra 0.6 μm, and the machining accuracy of the
blade profile is 0.05–0.07mm.
© 2016 The Authors.
© Authors. Published
PublishedbybyElsevier
ElsevierB.V.
B.V. This is an open access article under the CC BY-NC-ND license
Peer-review under responsibility of the organizing committee of 18th CIRP Conference on Electro Physical and Chemical Machining (ISEM
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
XVIII).
Peer-review under responsibility of the organizing committee of 18th CIRP Conference on Electro Physical and Chemical Machining
(ISEM XVIII)
Keywords: Electrochemical machining; Titanium alloy; Ti60; Dissolution behavior; Blisk

1. Introduction manufacturing technology is required for machining such


alloys.
The high-temperature titanium alloy Ti60 (Ti–5.6Al– Electrochemical machining (ECM) is an electrochemical
4.8Sn–2Zr–1Mo–0.35Si–0.7Nd), which is a near-α titanium dissolution method to produce smooth surfaces with a high
alloy with an optimized chemical structure, has been used for accuracy and without limitations to the mechanical properties
manufacturing different components; the use of this alloy has of the alloys [6,7]. ECM is increasingly being considered as an
made it possible to increase the service temperature of the important method for the production of hard-to-machine
components to up to 600 °C [1,2]. Ti60 is an important titanium alloys. Compared to traditional technologies, ECM
structural material often used for manufacturing critical does not cause heat-affected zones and internal stresses on the
components of aero-engines, such as the blisks or blades of machining surface. In addition, because ECM causes no tool
high-pressure compressors, because of its low density wear and gives high material removal rates, it is a very cost-
combined with good high-temperature mechanical properties. effective and highly efficient production method.
However, machining such alloys by conventional methods is In recent years, many researchers have focused on the ECM
difficult, often resulting in low process efficiency, high tool of hard-to-machine materials, especially titanium alloys.
wear, and reduced precision. In addition, the surface integrity Weinmann et al. used different techniques like linear sweep
is often poor because of thermo-mechanically altered or voltammetry and electrochemical impedance spectroscopy to
damaged rim zones [3–5]. Therefore, an alternative study the electrochemical dissolution behavior of Ti90Al6V4
and Ti60Al40. They chose a suitable electrolyte and

2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of 18th CIRP Conference on Electro Physical and Chemical Machining (ISEM XVIII)
doi:10.1016/j.procir.2016.02.206
126 Zhengyang Xu et al. / Procedia CIRP 42 (2016) 125 – 130

corresponding current parameters [7]. Klocke et al. conducted 2. Experimental


basic research on the electrochemical machinability of
selected modern titanium and nickel alloys for aero-engine 2.1. Materials
components [6]. They also carried out technological and
economic comparisons of roughing strategies via milling, The workpiece material is the Ti60 alloy, which is made by
sinking electrical discharge machining (EDM), wire EDM, a conventional forging method in which the forging
and ECM for titanium and nickel blisks [8]. Clifton et al. temperature is below the phase transition point (1050–
investigated the surface characteristics and integrity of γ-TiAl 1060 °C). Fig. 1 shows the material morphology of the Ti60
subjected to ECM using perchlorate and chloride electrolytes alloy. In the microstructure of the conventionally forged Ti60,
[9]. Dhobe et al. performed experiments on the ECM of a major part is occupied by lumpy equiaxed primary α grains
commercially pure titanium using a sodium bromide and the dendritic secondary platelet α phase and the remaining
electrolyte at a tool feed rate of 0.1 mm/min. The roughness of β phase are interveined between the α grains.
the oxide-layered machined surface was suitable for use in
titanium implants without the need for further surface
preparation [10]. Santhi et al. optimized the process
parameters in ECM using DFA-fuzzy set theory-TOPSIS for a
titanium alloy [11]. Ittah et al. evaluated the pitting corrosion
of titanium in ammonium bromide solutions by
electrochemical methods [12]. Qu et al. machined a titanium
alloy by wire ECM (WECM) and implemented axial
electrolyte flushing in WECM for removing electrolysis
products and renewing the electrolyte [13]. Zaytsev et al.
proposed the optimal conditions for the ECM of Ti–6Al–4V Fig. 1. Microstructure of Ti60 material.
titanium alloy using a microsecond pulsed current; under these
conditions, surface-layer hydrogen was not found and pitting 2.2. Experimental setup and sample preparation
did not occur [14]. Mount et al. carried out theoretical analysis
of chronoamperometric transients in ECM and characterized The structure and components of the samples used in the
titanium 6/4 and Inconel 718 alloys [15]. Lu and Leng study were characterized by using a metalloscope and by
employed jet-electrochemical micromachining to produce energy-dispersive X-ray spectroscopy (EDX). The
micro-hole patterns on titanium specimens [16]. Sjöström and metalloscope is a Zeiss Axioplan 2 Imaging & Axiophot 2
Su presented a technique involving a water-free electrolyte microscope. The EDX investigations were performed using
that can be used to perform electrochemical micromachining another microscope (JSM-6360LV, JEOL, Japan).
of Ti surfaces. Pit and groove structures with approximately Electrochemical measurements were performed using a
50-μm diameter/width were fabricated by using a tungsten three-electrode setup and an electrochemical workstation
carbide tool [17]. Weber et al. studied the electrochemical (CHI660E, CH Instruments Inc., China). The counter
dissolution of cast iron in NaNO3 electrolyte [18]. electrode was a platinum flat electrode, the reference
The main problem in using ECM for titanium alloys is electrode was Hg/Hg2SO4 in 0.5 M sulfuric acid, and the
titanium self-passivation, whereby a passive oxide layer is working electrode was a Ti60 cuboid (10 × 10 × 5mm) whose
formed, which inhibits the dissolution process. A propriate five surfaces were covered with resin and only one surface
process parameters and a suitable electrolyte are important for was exposed to pretreatment using wet abrasive papers and
the machining. This study focuses on the ECM of the high- rinsing with distilled water. The actual volume
temperature titanium alloy Ti60. The electrochemical electrochemical equivalent (ηω)–current density (i) curve was
dissolution behavior of Ti60 is analyzed. The anodic obtained by using a custom-made ECM experimental system
polarization curves of Ti60 with sodium nitrate and sodium with a single feeding axis (Fig. 2). The experiments involving
chloride solutions are obtained, and a suitable electrolyte is the comparison of the machining surfaces roughness with
chosen. The open circuit potential and the actual volume different current densities were performed for the same
electrochemical equivalent–current density curve of Ti60 are machine tool. Cubes with dimensions 10 × 10 × 10 mm were
obtained. Dissolution experiments are performed at different used as samples during the experiments. Finally, a blisk sector
current densities, and the results show that the surface made of Ti60, intended for use in an aero-engine compressor,
roughness of Ti60 undergoing ECM deteriorates when the was machined electrochemically using custom-made blisk
current density is small. Finally, electrochemical parameters ECM machine tools such as a blisk channel ECM machine
are optimized and the blisk sector made of Ti60, which is to tool and profile ECM machine tool (Fig. 3). The surface
be used in an aero-engine compressor, is machined by ECM. roughness was measured using a surface-finish measuring
instrument (Perthometer S3P, Mahr GmbH, Germany). The
machining accuracy of the blade profile was measured using a
coordinate measuring machine (TESA Micro-Hite 3D, TESA,
Switzerland).
Zhengyang Xu et al. / Procedia CIRP 42 (2016) 125 – 130 127

The current–voltage curves show that the electrolyte


composition as well as the concentration influence the
dissolution behavior of the material. Based on the
measurements for sodium chloride shown in Fig. 5, the curves
can be divided into two different regions. Between 0 and 2 V,
the curves show a distinct area of passivation. There is no
electrochemical dissolution, and currents are almost zero
because the potentials are below the dissolution voltage (Ediss).
When the potentials are more than 2 V, the currents increase
Fig.2. Single-feeding-axis ECM experimental system. gradually, which means that electrochemical dissolution
occurs. This area is called the transpassive region. There is a
chemical interaction between chloride ions and the oxide
surface. Chloride ions with small sizes and strong
adsorptive properties can penetrate the passive layer and react
with the base alloy, resulting in the destruction of the oxide
layer. The dissolution voltages can be determined by
evaluating the inflection points of the polarization curves.
Electrolyte concentration is an important factor governing
Fig. 3. Custom-made blisk ECM machine tools. the dissolution behavior. In the measurements, several
different concentrations (0.1%, 1%, 5%, 10%, and 15%) were
3. Results and discussion chosen. For low-concentration electrolytes (0.1% and 1%),
Ediss was higher than that for the other higher-concentration
3.1. Composition of material samples solutions (5%, 10%, and 15%). Furthermore, the increase in
current levels is very slow when the concentration is low
The composition of the Ti60 alloy samples was analyzed by (0.1% and 1%). Especially, for the electrolyte with 0.1%
EDX, as shown in Fig. 4. The results for the sample that concentration, there is almost no obvious dissolution and the
underwent polish pretreatment are shown in Fig. 4(a). The material is still in passivation. In contrast, for higher-
elements are almost in accordance with the nominal concentration solutions (5%, 10%, and 15%), the currents
composition of a Ti60 alloy. Fig. 4(b) shows the composition increase rapidly and steep ascending gradients are achieved.
of the sample without pretreatment. Because titanium is a Therefore, for higher concentrations, faster transpassive
self-passivation metal and there is a passive oxide layer on the dissolution is observed.
sample surface, oxygen is detected. 40°C NaCl (0.1% wt)
40°C NaCl (1% wt)
Element Wt% At% Element Wt% At% 40°C NaCl (5% wt)
7 Al 04.97 08.92 7
Ti
O 04.02 11.24 0.4 40°C NaCl (10% wt)
Ti Si 01.10 01.90 Al 04.43 07.34 40°C NaCl (15% wt)
6 Zr 03.10 01.65 6 Si 00.88 01.41
Nb 01.14 00.59 Zr 02.80 01.37
5 Mo 00.74 00.38 5
Nb 00.96 00.46 0.3
Sn 03.88 01.58
Intensity/a.u.
Intensity/a.u.

Mo 00.62 00.29
Current/A

4 Ti 83.49 84.47 4
Sn 03.46 01.30
Fe 00.13 00.11
Ti 81.14 75.79
3 Ta 01.45 00.39 3
Fe 00.66 00.53 0.2

Ta 01.03 00.25
2 2


1 Al Zr Mo 1 Al Zr Mo
0.1
Si Nb Sn Fe Ta O Si Nb Sn Fe Ta
0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9
Energy/keV Energy/keV 0.0
0 1 2 3 4 5 6 7 8 9 10
(a) (b)
Potential/V

Fig. 4. Composition of Ti60 alloy samples: (a) sample with pretreatment and
Fig. 5. Polarization curves for Ti60 alloy in sodium chloride with different
(b) sample without pretreatment.
concentrations.

3.2. Electrochemical characterization Electrolyte temperature is another important factor


influencing the dissolution behavior. In the present work, six
In a series of measurements, the influence of different different temperatures (10, 20, 30, 40, 50, and 60 °C) were
electrolytes and temperatures on the electrochemical used. Fig. 6 shows the current–voltage curves for the sodium
dissolution behavior of the Ti60 alloy was investigated by chloride electrolyte with 10% concentration and
using the polarization curve and the time-dependent evolution abovementioned temperatures. The curves can be divided into
of the open circuit potential (EOCP). Two kinds of two groups. For the group of low-temperature electrolytes (10,
electrolytes—sodium nitrate and sodium chloride solutions— 20, and 30 °C), Ediss values are quite high (around 6 V). This
were selected for the measurements. Fig. 5 shows the indicates that it is difficult for electrochemical dissolution to
polarization curves for the Ti60 alloy in sodium chloride with continue at low electrolyte temperatures. In contrast, when the
different concentrations. The electrolyte temperature was temperature is more than 40 °C, Ediss values clearly decline
always 40 °C during the experiments. The scan rate of voltage (only approximately 2 V). The dissolution starts at lower
in the experiments is 0.01V/s, so the time of each experiment voltages, which indicates better machinability.
is about 1000 seconds. Electrochemical dissolution occurs more easily when the
128 Zhengyang Xu et al. / Procedia CIRP 42 (2016) 125 – 130

temperature is higher. A possible explanation for the corresponds to the dissolution resistance. The influence of the
differences among different electrolyte temperatures might be oxidation power of different anions is measured by a time-
the velocity of reactive ion exchange, considering the kinetic resolved recording of EOCP. The Ti60 samples are immersed in
and thermodynamic effects. At low temperatures, the velocity sodium chloride and sodium nitrate electrolytes with 10%
of reactive ion exchange could be assumed to be lower. This concentration and different temperatures, and EOCP is
affects the chemical interaction between the oxide layer and measured for 1000 s. Fig. 8 shows the time dependence of the
chloridion; hence, the continuation of electrochemical EOCP of Ti60 in different electrolytes and temperatures. The
dissolution becomes difficult. increase in EOCP indicates the generation of the oxide layer. If
10°C NaCl (10% wt)
20°C NaCl (10% wt) the oxide layer is removed, electrochemical dissolution will
30°C NaCl (10% wt)
0.4 40°C NaCl (10% wt)
50°C NaCl (10% wt)
be accelerated, and then, EOCP will decrease. From Fig. 8, it
60°C NaCl (10% wt)
can be concluded that the formation of the oxide layer is faster
0.3
in the nitrate electrolyte than in the chloride electrolyte
Current/A

0.2 because the EOCP of Ti60 in the nitrate electrolyte is always


0.1
higher than that in the chloride electrolyte. In addition, the
higher the electrolyte temperature, the lower is the value of
0.0
0 1 2 3 4 5 6 7 8 9 10 EOCP. The abovementioned results indicate that better
Potential/V machinability can be obtained by using the chloride
electrolyte with a higher temperature.
Fig. 6.Current–voltage curves for sodium chloride electrolyte with 10% 40°C NaCl (10% wt) passivation
30°C NaNO3 (10% wt)
0.2 0.8
concentration and different temperatures. 40°C NaNO3 (10% wt)
0.6
30°C NaCl (10% wt)
40°C NaCl (10% wt)
50°C NaNO3 (10% wt) 50°C NaCl (10% wt)
0.4
0.0
0.2
Fig. 7 shows the current–voltage curves for Ti60 in sodium

Potential/V
Potential/V
0.0
-0.2
-0.2
nitrate electrolyte with 10% concentration and different -0.4
-0.4
temperatures. Compared to the sodium chloride electrolyte, -0.6
-0.8
the curves of the sodium nitrate electrolyte are very different. -0.6
0 200 400 600 800 1000
-1.0
0 200 400 600 800 1000
At a low temperature (30 °C), the current is almost zero Time/s Time/s

during the entire measurement. This indicates that the material (a) (b)
is still passive and the oxide layer is not destroyed. When the Fig. 8. Time dependence of EOCP of Ti60 in different electrolytes and
temperature is 40 °C, a tiny electrochemical reaction occurs. temperatures: (a) NaCl solution and (b) NaNO3 solution.
The current increases slightly and then declines to zero. This
demonstrates that there is only little corrosive pitting on the The actual volume electrochemical equivalent (ηω)–current
surface and then the oxide layer is generated again. At a density (i) curve for Ti60 in the sodium chloride with the 10%
higher temperature (50 °C), the current increases slowly, concentration and 40 °C temperature is obtained according to
which indicates the occurrence of a hybrid reaction involving the abovementioned results using the custom-made ECM
oxide layer generation and pitting dissolution. When the machine tool, as shown in Fig. 9. Here, η is the current
potential is more than 9 V, the current curve becomes serrated. efficiency, and ω is the volume electrochemical equivalent.
A possible explanation for this is that with an increase in the The curve can be divided into two regions. Between 0 to 20
potential, pitting corrosion is generated on some areas of the A/cm2, the actual volume electrochemical equivalent
surface and the current increases rapidly. However, because increases sharply. This phenomenon indicates that
sodium nitrate solution is an inactive electrolyte and has electrochemical dissolution becomes stronger as the current
higher oxidation power than halide electrolytes, pitting can be density increases. When the current density is more than 20
oxidized immediately and hence the current declines almost A/cm2, ηω remains stable and hardly changes in this
linearly. measurement range. This demonstrates that the experiment is
30°C NaNO3 (10% wt) in the state of steady electrochemical dissolution. In addition,
40°C NaNO3 (10% wt)
0.4 50°C NaNO3 (10% wt) based on ECM theory, the dissolution velocity of the anode
0.3
workpiece is proportional to ηω and i. Thus, increasing the
current density of ECM not only enhances the dissolution
Current/A

0.2
velocity but also improves ηω, which can further enhance the
0.1 dissolution velocity of the anode workpiece. Fig. 10 shows the
experiment samples machined at different current densities in
0.0
0 1 2 3 4 5 6 7 8 9 10 the NaCl electrolyte with 10% concentration and 40 °C
Potential/V temperature. When the current density is 50 A/cm2, the
machined plane is very smooth. In contrast, when the current
Fig. 7. Current–voltage curves for Ti60 in sodium nitrate electrolyte with
10% concentration and different temperatures. density is 10 A/cm2, the electrochemical dissolution is uneven
and pitting corrosion is observed on the workpiece surface.
The same results can be obtained by measuring the open Thus, a high current density, more than at least 20 A/cm2, is
circuit potential (EOCP) of Ti60 in an electrolyte, which beneficial to ECM stability, efficiency, and quality.
Zhengyang Xu et al. / Procedia CIRP 42 (2016) 125 – 130 129

Table 1. ECM experimental parameters.


0.0018

0.0016 Item Value


Workpiece material Ti60

ηω/(cm3·A-1·min-1)
0.0014

0.0012 Cathode material 1Cr18Ni9Ti


0.0010 Electrolyte NaCl (10%)
0.0008 Voltage 30 V
0.0006 Inlet pressure 0.5 MPa
0 10 20 30 40 50 60 70 80 90
Temperature 40 ± 0.1°C
Current density/(A·cm-2)
Initial gap 0.5 mm
Fig. 9. Actual volume electrochemical equivalent (ηω)–current density (i) 1.2 mm/min (for channel)
curve for Ti60 in sodium chloride electrolyte with 10% concentration and Feed rate
0.5mm/min (for profile)
40 °C temperature.

Fig. 12 shows the workpiece samples machined


electrochemically. Fig. 12(a) shows the Ti60 workblank. Fig.
12(b) shows the sample after channel machining. The
maximum feeding rate of the cathode for channel machining
is approximately 1.5mm/min. When the feeding rate is
increased, the equilibrium gap between the end surface of the
cathode and the blisk hub gradually decreases. If the gap is
(a) (b) too small, the risk of short circuit increases; thus, a feeding
velocity of 1.2mm/min is selected for the stable ECM of the
Fig. 10. Surfaces produced by ECM at different current densities: (a) 10
A/cm2 and(b) 50 A/cm2.
blisk channel. Each channel can be machined within 30 min.
The best surface roughness of the blisk hub after ECM is Ra
3.3. ECM of Ti60 blisk sectors 0.6 μm.
Fig. 12(c) shows the blisk sector sample after profile
Experiments were performed on Ti60 blisk sectors using precision ECM. The concave and convex profiles of the blade
the custom-made blisk channel ECM machine tool and profile can be machined electrochemically at the same time. For
ECM machine tool. ECM processing of blisk blade profiles precision machining, the feeding rate of the cathode is
often happens in two steps. As shown in Fig. 11, the first step reduced to 0.5mm/min. However, because the working
is channel ECM processing, which creates several tens of allowance after channel machining for the subsequent
curved tunnels with allowances. The second step is blisk finishing is only 2 mm, each blade profile can be machined
profile finishing ECM, which produces blades with good within 5 min. The machining accuracy of the blisk profiles is
machining accuracy and surface roughness. measured using a coordinate measuring machine. Fig. 13
shows the machining error of the section lines on the blade
profile. Fig. 13(a) shows the concave profile, whereas Fig.
13(b) shows the convex profile. As the figure shows, the
(a) ECM error of the concave profile is approximately 0.05mm,
and the machining error of the convex profile is
approximately 0.07mm.

(b)

Fig. 11.Two steps of blisk ECM:(a) channel machining and (b) blade profile
machining.

Tool electrode
The main experimental parameters are listed in Table 1. (a) (b)
The workpiece material was Ti60. The cathode was fabricated
from stainless steel to make it impervious to corrosion. Based
on the above mentioned electrochemical behavior of Ti60,
sodium chloride with 10% concentration was used as the
electrolyte because of its good activity. The temperature of
the electrolyte was 40 °C. Current density plays an important
Tool electrode
role in ensuring stable machining and producing a good
(c)
surface finish on titanium; thus, parameters such as
temperature and voltage were set to high values for obtaining Fig. 12. (a) Ti60 workblank, (b) sample after channel machining, and (c)
a higher current density during the process. sample after blade profile machining.
130 Zhengyang Xu et al. / Procedia CIRP 42 (2016) 125 – 130

0.15 line1 Acknowledgements


line2
line3
0.10 line4
line5
line6
This study was sponsored by the Program for New Century
Excellent Talents in University (NCET-12-0627) and by the
Machining error/mm
0.05

Fundamental Research Funds for the Central Universities


0.00 (NE2014104).
-0.05
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