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Enhanced Metal Surface Processing Through the No-Stray-Corrosion Controllable Electrolyte DistributionElectrochemical

Jiankang Wang1, Qiyuan Cao2, Ye Chen3

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|July 30, 2025
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Summary

A new controllable electrolyte distribution ECM (CED-ECM) method prevents stray corrosion in metal surface processing. This validated simulation framework enables user-defined surface profiles for advanced applications.

Keywords:
controllable electrolyte distribution ECM (CED-ECM)metal surface processingmodeling and simulationno-stray-corrosion ECM methodwater-absorbent porous ball

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Area of Science:

  • Materials Science and Engineering
  • Manufacturing Processes

Background:

  • Electrochemical Machining (ECM) is a widely used metal surface processing technique.
  • A significant drawback of ECM is stray corrosion caused by the electrolyte.
  • Existing ECM methods have limitations in preventing this unwanted corrosion.

Purpose of the Study:

  • To address the stray corrosion issue in ECM.
  • To develop and validate a novel no-stray-corrosion ECM method: controllable electrolyte distribution ECM (CED-ECM).
  • To explore the practical application and potential of the CED-ECM method in metal surface processing.

Main Methods:

  • Simulated the electrochemical machining process using COMSOL Multiphysics.
  • Validated simulation outcomes with practical experimental observations.
  • Applied the CED-ECM method to SUS304 stainless steel workpieces.

Main Results:

  • Developed a validated simulation framework for the CED-ECM process.
  • Successfully applied CED-ECM to SUS304 workpieces, achieving diverse cross-sectional profiles.
  • Demonstrated the ability to create user-defined surface profiles by controlling pass intervals.

Conclusions:

  • The CED-ECM method effectively overcomes stray corrosion in electrochemical machining.
  • The validated simulation framework provides a reliable tool for CED-ECM process design.
  • This research opens new avenues for surface texturing and advanced manufacturing applications using controlled surface profiles.