Fabrication of submillimetre structures on pure titanium by non-aqueous electrolyte jet machining

Titanium and its alloys are widely utilized in the field of aerospace and medical devices, owing to their impressive high-temperature durability and excellent corrosion resistance. Many researchers have machined millimeter-scale features on titanium using electrochemical jet machining (EJM). However, achieving submillimetre scale features on titanium with high efficiency and surface integrity is still a hindrance. In this research, a small nozzle with a diameter of 200 μm has been proposed for EJM of pure titanium (TA2) with NaCl-ethylene glycol (EG) solution. This non-aqueous electrolyte is able to prevent the formation of oxide layers during the machining process. In the experimental part, the utilization of EJM in processing dimples and channels on TA2 has been examined. The direct current mode and the pulsed current mode have been compared in terms of dimensions, surface finish, and material removal localization. It is found that by utilizing suitable parameters, EJM with non-aqueous electrolyte is suitable to manufacture submillimetre structures on pure titanium with high precision and high surface quality.