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<p>This study investigates the effect of cryogenic treatment on electrodes made from Beryllium Copper (BrCu), Stainless Steel (SS304), and Sterling Silver (Ag) during the electrochemical micro-machining (ECM) process applied to WAAM-fabricated SS316L material. To improve machining accuracy and efficiency, the research explores how cryogenic treatment affects key machining parameters, such as material removal rate (MRR), overcutting, and circularity. The experimental design utilized Response Surface Methodology (RSM) from Design Expert v13 to evaluate the effects of voltage, frequency, and electrolyte concentration on the ECM process at different duty cycle settings. XGBoost machine learning was employed to predict ECM outcomes, with R<sup>2</sup> values of 0.9823 for MRR, 0.9892 for Circularity, and 0.9944 for Overcut, demonstrating the model’s predictive accuracy. Electrical conductivity analysis revealed a significant improvement in SS304 conductivity post-cryogenic treatment, enhancing its ion exchange capabilities and contributing to more stable machining. SEM microstructure analysis showed that the DCT-treated electrodes exhibited smoother grain structures, improving their performance in ECM. Among the electrodes, BrCu exhibited the highest MRR (9.8773&#xa0;µg/s), SS304 demonstrated the lowest circularity deviation (13.3364&#xa0;µm), and Ag produced the lowest overcut (177.557&#xa0;µm). These findings have important implications for aerospace, automotive, and medical devices, where high surface quality, dimensional accuracy, and optimized material removal are critical. This research provides valuable insights for enhancing precision machining in these sectors, offering practical solutions for improving ECM performance in WAAM-fabricated SS316L.</p> Graphical abstract <p></p>

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Effect of cryogenic treatment on different electrodes to enhance electrochemical machining of WAAM-fabricated SS316L steel

  • 期刊论文

  • 发表日期：

    2025年6月16日

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  • Sethuraman Arumugam,
  • Vijayaragavan Elumalai,
  • Lakshmanan Thangavelu,
  • Geethapriyan Thangamani

摘要

This study investigates the effect of cryogenic treatment on electrodes made from Beryllium Copper (BrCu), Stainless Steel (SS304), and Sterling Silver (Ag) during the electrochemical micro-machining (ECM) process applied to WAAM-fabricated SS316L material. To improve machining accuracy and efficiency, the research explores how cryogenic treatment affects key machining parameters, such as material removal rate (MRR), overcutting, and circularity. The experimental design utilized Response Surface Methodology (RSM) from Design Expert v13 to evaluate the effects of voltage, frequency, and electrolyte concentration on the ECM process at different duty cycle settings. XGBoost machine learning was employed to predict ECM outcomes, with R2 values of 0.9823 for MRR, 0.9892 for Circularity, and 0.9944 for Overcut, demonstrating the model’s predictive accuracy. Electrical conductivity analysis revealed a significant improvement in SS304 conductivity post-cryogenic treatment, enhancing its ion exchange capabilities and contributing to more stable machining. SEM microstructure analysis showed that the DCT-treated electrodes exhibited smoother grain structures, improving their performance in ECM. Among the electrodes, BrCu exhibited the highest MRR (9.8773 µg/s), SS304 demonstrated the lowest circularity deviation (13.3364 µm), and Ag produced the lowest overcut (177.557 µm). These findings have important implications for aerospace, automotive, and medical devices, where high surface quality, dimensional accuracy, and optimized material removal are critical. This research provides valuable insights for enhancing precision machining in these sectors, offering practical solutions for improving ECM performance in WAAM-fabricated SS316L.

Graphical abstract