Surface quality evaluation of electrical discharge machined AZ31 magnesium alloy

Results in Materials Pub Date : 2025-08-09 DOI:10.1016/j.rinma.2025.100751

Saeed Asghari , Mohammad Reza Shabgard , Maghsoud Shalvandi , Farzad Habibi

引用次数: 0

Abstract

This research optimizes electrical discharge machining (EDM) of AZ31 magnesium alloy by investigating pulse-on time (6.4–400 μs) and peak current (12–48 A) by the aid of image processing technique and phase identification. Higher energy inputs increased material removal and tool wear rates but also raised crack density (up to 5.2 %) and surface roughness (R_a up to 16.41 μm). Crucially, pulse-on times below 10 μs eliminated surface cracks entirely. Minimal roughness (R_a = 1.53 μm) occurred at 12A/6.4μs, while surface hardness rose to 152 HV at high energies due to alloying. Metastable Mg₂C₃ carbide was identified via XRD as a product of rapid EDM cooling. Multi-objective optimization recommends 24A/25μs for balanced efficiency (MRR: 4.2 mm³/min) and surface quality (R_a: 2.87 μm, 0.3 % cracks), while 12A/6.4 μs is ideal for biomedical implants.

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电火花加工AZ31镁合金表面质量评价

利用图像处理技术和相位识别技术，研究了AZ31镁合金的脉冲开启时间（6.4 ~ 400 μs）和峰值电流（12 ~ 48 A），优化了AZ31镁合金的电火花加工工艺。更高的能量输入增加了材料去除率和刀具磨损率，但也增加了裂纹密度（高达5.2%）和表面粗糙度（Ra高达16.41 μm）。关键是，低于10 μs的脉冲开启时间完全消除了表面裂纹。在12A/6.4μs时，表面粗糙度最小（Ra = 1.53 μm），而在高能下，由于合金化，表面硬度上升到152 HV。通过x射线衍射（XRD）鉴定了快速电火花加工冷却后的亚稳态Mg2C3碳化物。多目标优化推荐24A/25μs，以平衡效率（MRR: 4.2 mm3/min）和表面质量（Ra: 2.87 μm， 0.3%裂纹），而12A/6.4 μs是理想的生物医学植入物。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Results in Materials

CiteScore

5.30

自引率

0.00%

发文量