Effect of Aqueous Electrolyte Composition on Efficiency of Electrochemical Post-Processing of Additive Manufacturing Products from Ti-6Al-4V Alloy Obtained by Selective Electron Beam Melting

The influence of the anionic composition of an aqueous electrolyte on the efficiency of the electrochemical leveling of the initial microgeometry of samples obtained by the selective electron beam melting (SEBM) at the following mode parameters was studied: current density – 20 A/cm2, initial interelectrode gap – 0.3 mm, average speed of electrolyte pumping – 12 m/c. Aqueous solutions of sodium chloride, nitrate, perchlorate and bisalt electrolytes based on them were studied. It was that aqueous solutions of sodium perchlorate have the best microleveling properties among the studied working media, which provides the ability to reduce the parameters Ra and Rz from values of 35 and 180 μm, respectively, to values of 3.2 and 20 μm during electrolysis of 30 s in a direct-flow electrolyzer. It was established that the microgeometry leveling corresponds to the model of the secondary distribution of dissolution rates; two main factors were identified that significantly influenced on the result: polarization of the electrodes and a decrease in the oxidation state of metal ions passing into the solution during electrochemical machining in the vicinity of the depression in relation to the protrusion due to changes in the local conditions of electrolysis. Microetching along grain boundaries in the studied electrolytes was not detected at the accepted parameters of the electrolysis mode.