Electroplasticity-assisted manufacturing of difficult-to-machine materials: Mechanisms, process design, and outlook
摘要
Difficult-to-machine materials, such as titanium alloys, nickel-based superalloys, and hard–brittle ceramics, are widely used in aerospace, energy, and defense fields owing to their excellent mechanical and service properties. However, conventional processing of these materials often suffers from high deformation resistance, severe tool wear, poor surface integrity, and low machining efficiency. The electroplastic effect has emerged as a promising energy-field-assisted manufacturing method because externally applied electric current can reduce flow stress, improve plastic deformation behavior, and enhance process performance. Unlike previous reviews that mainly focus on electroplasticity-assisted cutting, this review extends the scope to a broader framework of electroplasticity-assisted manufacturing and establishes a “mechanism–process–performance–outlook” structure. First, the fundamental mechanisms of electroplasticity, including electron wind force, dislocation depinning, Joule heating, and the skin effect, are summarized, with emphasis on the coupling between thermal and athermal effects. Second, recent advances in electroplasticity-assisted cutting, grinding, rolling, drawing, and other forming processes are reviewed, focusing on the effects of electrical assistance on processing load, tool wear, surface integrity, and deformation behavior. Furthermore, this review highlights the transition from single-current assistance to multi-energy-field hybrid processing, such as electro–ultrasonic and electropulsing–laser hybrid approaches, and reveals their potential for low-damage and high-efficiency manufacturing. Finally, current challenges are discussed, including thermal/athermal effect decoupling, standardization of electrical parameters, interfacial reliability, multi-physics modeling, and process optimization, providing guidance for further development of electroplasticity-assisted manufacturing of difficult-to-machine materials.