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<p>To address the high surface roughness (Ra &gt; 10&#xa0;μm) of the inner surfaces of AlSi10Mg alloy channels produced by selective laser melting (SLM) and the difficulty of achieving both efficiency and uniformity using conventional finishing methods, a combined electrochemical–abrasive erosion finishing method is proposed. First, electrochemical finishing rapidly dissolves microscopic surface protrusions and adhered powder. This is followed by abrasive erosion that removes the passivation layer and further reduces surface roughness. A flexible helical insulated tool electrode is designed. Through flow field simulations and process experiments, the influence of the upper and lower guide tube lengths on flow field characteristics and finishing effects is investigated. Simulations and experiments indicate that adding a 10–15&#xa0;mm upper guide tube suppresses abrupt changes in inlet velocity, while a 15–20&#xa0;mm lower guide tube significantly improves outlet flow field stability. Optimal machining uniformity along the entire channel is achieved with a 15&#xa0;mm upper guide tube and a 20&#xa0;mm lower guide tube. Using these process parameters (electrochemical finishing: 15&#xa0;V, 30&#xa0;s, 10% choline chloride; abrasive erosion: 15&#xa0;m/s, 10&#xa0;min, 10% silicon carbide), combined electrochemical–abrasive erosion finishing of SLM-fabricated AlSi10Mg channels with lengths of 20&#xa0;mm and 50&#xa0;mm reduces the internal surface roughness from an initial Ra of 10.986&#xa0;μm to approximately 4.5&#xa0;μm, with a uniform distribution along the channel axis. This method enables efficient and uniform finishing of the inner surfaces of SLM-fabricated AlSi10Mg channels, offering an effective approach to post-processing complex internal channels in additive manufacturing.</p>

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Flow field design for combined electrochemical–abrasive erosion finishing of SLM-fabricated channels

  • 期刊论文

  • 发表日期：

    2026年7月22日

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  • Suwei Xia,
  • Tao Yang,
  • Xiujuan Wu,
  • Ming Li,
  • Yusen Hang,
  • Lin Cheng

摘要

To address the high surface roughness (Ra > 10 μm) of the inner surfaces of AlSi10Mg alloy channels produced by selective laser melting (SLM) and the difficulty of achieving both efficiency and uniformity using conventional finishing methods, a combined electrochemical–abrasive erosion finishing method is proposed. First, electrochemical finishing rapidly dissolves microscopic surface protrusions and adhered powder. This is followed by abrasive erosion that removes the passivation layer and further reduces surface roughness. A flexible helical insulated tool electrode is designed. Through flow field simulations and process experiments, the influence of the upper and lower guide tube lengths on flow field characteristics and finishing effects is investigated. Simulations and experiments indicate that adding a 10–15 mm upper guide tube suppresses abrupt changes in inlet velocity, while a 15–20 mm lower guide tube significantly improves outlet flow field stability. Optimal machining uniformity along the entire channel is achieved with a 15 mm upper guide tube and a 20 mm lower guide tube. Using these process parameters (electrochemical finishing: 15 V, 30 s, 10% choline chloride; abrasive erosion: 15 m/s, 10 min, 10% silicon carbide), combined electrochemical–abrasive erosion finishing of SLM-fabricated AlSi10Mg channels with lengths of 20 mm and 50 mm reduces the internal surface roughness from an initial Ra of 10.986 μm to approximately 4.5 μm, with a uniform distribution along the channel axis. This method enables efficient and uniform finishing of the inner surfaces of SLM-fabricated AlSi10Mg channels, offering an effective approach to post-processing complex internal channels in additive manufacturing.