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<p>Electrochemical machining (ECM) is extensively applied across various industries, including aerospace, defense, automotive and medical fields, where surface roughness has become a key quality concern due to heightened performance expectations. Fe-based shape memory alloys are used in many industries including aviation, automobile manufacturing and medical equipment because of their low density, extraordinary corrosion resistance and high specific strength. The micro-features generated on Fe-based SMAs also hold significant application potential in biomedical micro-actuators, aerospace adaptive components, and MEMS-based smart devices due to their high corrosion resistance, biocompatibility and shape recovery characteristics. In the present research, micro-holes were fabricated in Fe-based shape memory alloy under varying concentrations of NaNO<sub>3</sub> electrolyte solution through an in-house-developed µECM process. The machining performance was assessed based on material removal rate (MRR), surface roughness (SR) and radial overcut (ROC) to understand the effect of electrolyte concentration on machining efficiency, surface quality and dimensional accuracy. Electrochemical impedance spectroscopy (EIS) and polarization curves were analyzed to study the alloy’s electrochemical behavior, corrosion resistance and reaction kinetics in NaNO<sub>3</sub>solution. The optimal machining parameters 14&#xa0;V, 40&#xa0;g/l NaNO<sub>3</sub> concentration and 0.12&#xa0;mm/s feed rate yielded an MRR of 0.679&#xa0;mg/min, SR of 1.366&#xa0;µm and ROC of 0.781&#xa0;mm, achieving a balanced combination of material removal efficiency and machining precision.</p>

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On the Electrochemical Behavior and Surface Integrity Aspects of Fe-Shape Memory Alloy Processed via µ-Electrochemical Machining with NaNO3 Solution

  • 期刊论文

  • 发表日期：

    2026年3月21日

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  • Rishikant Mishra,
  • Ravi Pratap Singh,
  • R. K. Garg

摘要

Electrochemical machining (ECM) is extensively applied across various industries, including aerospace, defense, automotive and medical fields, where surface roughness has become a key quality concern due to heightened performance expectations. Fe-based shape memory alloys are used in many industries including aviation, automobile manufacturing and medical equipment because of their low density, extraordinary corrosion resistance and high specific strength. The micro-features generated on Fe-based SMAs also hold significant application potential in biomedical micro-actuators, aerospace adaptive components, and MEMS-based smart devices due to their high corrosion resistance, biocompatibility and shape recovery characteristics. In the present research, micro-holes were fabricated in Fe-based shape memory alloy under varying concentrations of NaNO3 electrolyte solution through an in-house-developed µECM process. The machining performance was assessed based on material removal rate (MRR), surface roughness (SR) and radial overcut (ROC) to understand the effect of electrolyte concentration on machining efficiency, surface quality and dimensional accuracy. Electrochemical impedance spectroscopy (EIS) and polarization curves were analyzed to study the alloy’s electrochemical behavior, corrosion resistance and reaction kinetics in NaNO3solution. The optimal machining parameters 14 V, 40 g/l NaNO3 concentration and 0.12 mm/s feed rate yielded an MRR of 0.679 mg/min, SR of 1.366 µm and ROC of 0.781 mm, achieving a balanced combination of material removal efficiency and machining precision.