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Electrochemical Machining (ECM) is a prominent non-traditional machining technique suitable for processing advanced materials like Inconel 718, a nickel-based superalloy known for its high strength, hardness, and corrosion resistance. Due to these properties, conventional machining often faces tool wear and low efficiency, making ECM a preferable alternative. In this study, the ECM of Inconel 718 was performed using a copper cathode to evaluate the influence of various process variables such as voltage, electrolyte composition, and electrolyte temperature on material removal rate (MRR) and surface roughness (Ra). An electrolytic composition of 75% NaCl and 25% NaNO₃ exhibited the highest MRR, while the lowest was observed at 30 °C of an electrolyte temperature. Response Surface Methodology (RSM) was employed to optimize the input parameters. The machined surfaces were examined using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS), revealing that electrolyte composition significantly affects both MRR and surface finish. The study highlights ECM’s potential for achieving high-efficiency and precision machining of superalloys.

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Performance Evaluation and Parametric Optimizations of Electrochemical Machining for Inconel 718

  • 会议论文

  • 发表日期：

    2026年

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  • Manjeet Kumar,
  • P. Sudhakar Rao

摘要

Electrochemical Machining (ECM) is a prominent non-traditional machining technique suitable for processing advanced materials like Inconel 718, a nickel-based superalloy known for its high strength, hardness, and corrosion resistance. Due to these properties, conventional machining often faces tool wear and low efficiency, making ECM a preferable alternative. In this study, the ECM of Inconel 718 was performed using a copper cathode to evaluate the influence of various process variables such as voltage, electrolyte composition, and electrolyte temperature on material removal rate (MRR) and surface roughness (Ra). An electrolytic composition of 75% NaCl and 25% NaNO₃ exhibited the highest MRR, while the lowest was observed at 30 °C of an electrolyte temperature. Response Surface Methodology (RSM) was employed to optimize the input parameters. The machined surfaces were examined using Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS), revealing that electrolyte composition significantly affects both MRR and surface finish. The study highlights ECM’s potential for achieving high-efficiency and precision machining of superalloys.