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<p>In electrochemical discharge machining (ECDM), the selection of a suitable electrolyte is a critical determinant of machining performance. This study demonstrates the synergistic effect of electric spark discharge and electrochemical dissolution through the use of electrolytes with varying compositions (30 wt% NaOH solution, 0.09 wt% NaCl solution, and their mixture) in conjunction with a rotating columnar tungsten electrode, leading to a significant improvement in machining efficiency and surface quality. The high-temperature alloy GH4169 was selected as the workpiece material, and this study investigated the influence of three electrolytes under varying machining voltages (25&#xa0;V, 35&#xa0;V, and 45&#xa0;V) on the material gap current waveforms, removal mechanisms, surface roughness, and morphological changes. The results revealed that the optimal processing performance was achieved using a mixture of 30 wt% NaOH and 0.09 wt% NaCl at 45&#xa0;V. The uniform electrolytic properties of the NaOH solution and the enhanced material removal capability of the NaCl solution synergistically improved processing efficiency, effectively minimized the recast layer thickness, and yielded a smoother workpiece surface. By comparing the processing outcomes across different electrolytes, this study concludes that selecting an appropriate electrolyte significantly optimizes processing performance, thereby offering valuable scientific insights for future research.</p>

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Effects of different electrolytes on electrochemical discharge machining performance

  • 期刊论文

  • 发表日期：

    2026年1月27日

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  • Hai Liu,
  • Xiaokang Chen,
  • Ajian Zhang,
  • Ning Ma,
  • Yulong Chen,
  • Qianlong Zhu

摘要

In electrochemical discharge machining (ECDM), the selection of a suitable electrolyte is a critical determinant of machining performance. This study demonstrates the synergistic effect of electric spark discharge and electrochemical dissolution through the use of electrolytes with varying compositions (30 wt% NaOH solution, 0.09 wt% NaCl solution, and their mixture) in conjunction with a rotating columnar tungsten electrode, leading to a significant improvement in machining efficiency and surface quality. The high-temperature alloy GH4169 was selected as the workpiece material, and this study investigated the influence of three electrolytes under varying machining voltages (25 V, 35 V, and 45 V) on the material gap current waveforms, removal mechanisms, surface roughness, and morphological changes. The results revealed that the optimal processing performance was achieved using a mixture of 30 wt% NaOH and 0.09 wt% NaCl at 45 V. The uniform electrolytic properties of the NaOH solution and the enhanced material removal capability of the NaCl solution synergistically improved processing efficiency, effectively minimized the recast layer thickness, and yielded a smoother workpiece surface. By comparing the processing outcomes across different electrolytes, this study concludes that selecting an appropriate electrolyte significantly optimizes processing performance, thereby offering valuable scientific insights for future research.