Dr. Yong Yang Profile

Dr. Yong Yang

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Proceedings Article | 16 October 2023 Paper

Micromoles drilling in Ti-6Al-4V titanium alloy by laser and electrochemical machining

Chenyu Sun, Yufeng Wang, Yong Yang, Yunfeng Liu, Wenwu Zhang

Proceedings Volume 12792, 127921F (2023) https://doi.org/10.1117/12.2691287

KEYWORDS: Laser processing, Titanium, Alloys, Electrodes, Electrolytes, Surface roughness, Radium, Sodium, Pulsed laser operation, Resistance

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Microholes are the key structure of core components in aerospace, precision instruments, and other fields. Both the machining accuracy and surface quality play a key role in the performance of the components. Titanium alloy has good high specific strength, excellent corrosion resistance, and super fracture toughness and fatigue properties, but its poor thermal conductivity, toughness, and large friction coefficient, result in the processing of titanium alloy deep small holes being more difficult. This paper proposes Laser and Shaped Tube Electrochemical Machining (Laser-STEM), which utilizes the total internal reflection to guide the laser to the machining zone. In Laser-STEM, the laser-induced local temperature rise of the electrolyte and direct processing could benefit the removal process of electrochemical machining of titanium alloy. Experiments were carried out using a liquid-core fiber-optic tube electrode with an electrolyte of 12.5% sodium nitrate solution while processing micro holes on Ti-6Al-4V titanium alloy. The effect of pulse voltage, laser power, and feeding rate on the machining accuracy of deep small-hole in titanium alloy was experimentally studied. With the increase in laser power, the machining gap increased by 34.74% and the side gap decreased by 24.13%. The experimental results show that the laser can improve the electrochemical machining accuracy. The experimental results showed that a deep hole without a recast layer of 1.5 mm in diameter and 50 mm in depth could be obtained in the Ti-6Al-4V workpiece at a processing voltage of 20 V, a laser power of 5 W and a feed rate of 1.2 mm/min. This paper verified the feasibility of processing deep and small holes in titanium alloy by combining laser and electrochemical machining, and provided a new solution for the high-efficiency processing of deep small holes and surface structures of titanium alloy.

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