Photocatalytic-assisted electrochemical machining of SiCp/Al: An exploration of mechanisms and effects.

Silicon carbide particle reinforced aluminum matrix composites (SiCp/Al), combine the properties of aluminum matrix materials and reinforced silicon carbide (SiC) particles, finding widespread application in aerospace, optics, and electronics. The increased hardness and electrochemical inertness of SiC particles present significant challenges in their processing. This research investigates the impact of photocatalytic processes on machining accuracy in electrochemical processing (ECM). The dissolution characteristics of SiCp/Al during ECM and photocatalytic-assisted electrochemical machining (PAECM) were analyzed with varying electrolyte compositions, using polarization curves and oxidation–reduction potential (ORP). Validation of improved machining accuracy and surface quality in PAECM was achieved through no-feeding machining. According to theoretical principles and laboratory analyses of the workpiece surface, it was found that PAECM, through its photocatalytic reaction, generated more oxides, blocked stray currents and stray corrosion effectively, and attained accuracy in profile creation. Through a comparative analysis it revealed that PAECM exhibited smoother profiles and reduced Overcut Ratio (OCR) in hole and groove machining compared to ECM, particularly in groove machining. Adjusting machining gaps as well as reducing abrasive particle size in PAECM influenced groove depth and width, which achieved optimal morphology with a 0.4 mm gap and a 2–3 nm abrasive particle size, resulting in a 370 μm depth. [ABSTRACT FROM AUTHOR]