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<p>To address the difficult-to-machine characteristics of tungsten-based alloys, this study proposes an ultrasonic-electric synergistic scraping (UESS) method. Through single-particle scraping experiments on WCu20 alloy, its machinability and material removal mechanisms are investigated. First, a theoretical model of the acoustic-electric composite field was established, Kinematic trajectory equations demonstrate that ultrasonic vibration effectively extends the scraping path, while dislocation dynamics theory confirms that the electron wind force and Joule heating effect accelerate dislocation slip and soften the material, respectively. Subsequently, comparative analyses were conducted on scratching force, surface integrity, and subsurface damage under conventional (CS) and assisted conditions (UAS, ES, UESS). Experimental results indicate that at a scratching speed of 0.20 m/s, the UESS process significantly reduces processing resistance. Its normal force (86.012 N) and tangential force (34.836 N) decreased by 24.58% and 24.55%, respectively, compared to the CS process. At a 35μm scratch depth, UESS significantly promoted plastic flow, increasing edge pile-up height by 43% (to 32.13&#xa0;μm) and markedly enhancing continuity. Microstructural analysis further confirmed UESS effectively suppressed surface oxidation. However, excessively high electrical parameters (120V/400Hz), while further reducing scratching force, induced microcrack propagation and accelerated oxidation. This study reveals a triple synergistic effect: “electron wind reduces dislocation resistance, Joule heating softens the matrix, and ultrasonic impact optimizes contact,” opening a new technological pathway for efficient, low-damage processing of tungsten alloys.</p>

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Study on Scratch Behavior and Material Removal of WCu20 Alloy Single Particles under Acoustic-Electrical Synergy

  • 期刊论文

  • 发表日期：

    2026年2月24日

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  • Mengpan Hu,
  • Zhanjie Li,
  • Chong Li,
  • Desheng Li,
  • Yonglin Min,
  • Gang Jin,
  • Zhiqiang Wang

摘要

To address the difficult-to-machine characteristics of tungsten-based alloys, this study proposes an ultrasonic-electric synergistic scraping (UESS) method. Through single-particle scraping experiments on WCu20 alloy, its machinability and material removal mechanisms are investigated. First, a theoretical model of the acoustic-electric composite field was established, Kinematic trajectory equations demonstrate that ultrasonic vibration effectively extends the scraping path, while dislocation dynamics theory confirms that the electron wind force and Joule heating effect accelerate dislocation slip and soften the material, respectively. Subsequently, comparative analyses were conducted on scratching force, surface integrity, and subsurface damage under conventional (CS) and assisted conditions (UAS, ES, UESS). Experimental results indicate that at a scratching speed of 0.20 m/s, the UESS process significantly reduces processing resistance. Its normal force (86.012 N) and tangential force (34.836 N) decreased by 24.58% and 24.55%, respectively, compared to the CS process. At a 35μm scratch depth, UESS significantly promoted plastic flow, increasing edge pile-up height by 43% (to 32.13 μm) and markedly enhancing continuity. Microstructural analysis further confirmed UESS effectively suppressed surface oxidation. However, excessively high electrical parameters (120V/400Hz), while further reducing scratching force, induced microcrack propagation and accelerated oxidation. This study reveals a triple synergistic effect: “electron wind reduces dislocation resistance, Joule heating softens the matrix, and ultrasonic impact optimizes contact,” opening a new technological pathway for efficient, low-damage processing of tungsten alloys.