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<p>In the recent duration, the research community was attracted towards environmental protection and health-related issues of working human operators through green and sustainable manufacturing. Electrochemical discharge machining (ECDM) was proven to be a potential contender to machine any type of material regardless of its characteristics because of its versatile applications in micro electro-mechanical systems, laboratory-on-chip devices, micro-fluidic devices, and the aerospace industry. Researchers had improved the performance of the ECDM process using different techniques, but the environmental aspects of the process were the least reported. The research paper highlighted the environmental aspects of the ECDM process in terms of fume mass concentration, morphological analysis of fume particles, particle size, and chemical composition of airborne particles. Fume mass concentration (FMC) was evaluated by changing the concentration of the electrolyte and the duty cycle. The obtained FMC varied from 28.7 to 109 mg m<sup>− 3</sup> with a change in the concentration of the electrolyte from 20 to 50%. Similarly, FMC varied from 24.3 to 65.0 mg m<sup>− 3</sup> with a change in the duty cycle from 60 to 90%. The least emission of fume particles during ECDM was reported at optimal parameters, that is, 20% concentration of electrolyte and 60% duty cycle. Morphological analysis revealed different shapes including irregular, spherical, and agglomerated forms. However, the average size of fume particles was generally less than 10 <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="10800_2025_2332_Article_IEq1.gif" Format="GIF" Height="12" Rendition="HTML" Resolution="72" Type="Linedraw" Width="15" /> </InlineMediaObject> <EquationSource Format="TEX">\(\:\mu\:\)</EquationSource> </InlineEquation>m. Metallic, toxic, and carcinogenic elements, namely copper, nickel, aluminum, titanium, magnesium, carbon, silicon, chromium, and others, were found during energy dispersive spectroscopy (EDS) analysis, which might have affected the health of human operators.</p> Graphical abstract <p></p>

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Fume particle concentration, elemental composition, and microstructural morphological characteristics in electrochemical discharge machining (ECDM) process

  • 期刊论文

  • 发表日期：

    2025年6月25日

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  • Santosh Kumar Yadav,
  • Abhishek Singh,
  • Sarbjit Singh,
  • Kishore Debnath,
  • Shubham Sharma,
  • Shashi Prakash Dwivedi,
  • P. Vijaya Kumar,
  • Varinder Singh,
  • Manish Jindal,
  • Abhinav Kumar

摘要

In the recent duration, the research community was attracted towards environmental protection and health-related issues of working human operators through green and sustainable manufacturing. Electrochemical discharge machining (ECDM) was proven to be a potential contender to machine any type of material regardless of its characteristics because of its versatile applications in micro electro-mechanical systems, laboratory-on-chip devices, micro-fluidic devices, and the aerospace industry. Researchers had improved the performance of the ECDM process using different techniques, but the environmental aspects of the process were the least reported. The research paper highlighted the environmental aspects of the ECDM process in terms of fume mass concentration, morphological analysis of fume particles, particle size, and chemical composition of airborne particles. Fume mass concentration (FMC) was evaluated by changing the concentration of the electrolyte and the duty cycle. The obtained FMC varied from 28.7 to 109 mg m− 3 with a change in the concentration of the electrolyte from 20 to 50%. Similarly, FMC varied from 24.3 to 65.0 mg m− 3 with a change in the duty cycle from 60 to 90%. The least emission of fume particles during ECDM was reported at optimal parameters, that is, 20% concentration of electrolyte and 60% duty cycle. Morphological analysis revealed different shapes including irregular, spherical, and agglomerated forms. However, the average size of fume particles was generally less than 10 \(\:\mu\:\) m. Metallic, toxic, and carcinogenic elements, namely copper, nickel, aluminum, titanium, magnesium, carbon, silicon, chromium, and others, were found during energy dispersive spectroscopy (EDS) analysis, which might have affected the health of human operators.

Graphical abstract