Electrolyte jet machining of Zr-based amorphous alloys in non-aqueous medium with assistance of magnetic field

Abstract Zr-based amorphous alloys are innovative materials with promising applications, such as biological sectors and sports facilities. This study evaluates the effects of magnetic field assistance on electrolyte jet machining (EJM) of these alloys in alcohol-based electrolyte. Firstly, the electrochemical-induced interface structural evolution at different regions is examined to elucidate the dissolution mechanism of Zr-based amorphous alloys in the NaCl ethylene glycol electrolyte via atomic structural analysis. Then, based on the Cl¯ diffusion coefficients in the diffusion region and convection region of the inter-electrode gap calculated from the molecular dynamics (MD) simulation, the magnetic field is found to increase the total diffusion coefficient of Cl¯ in the diffusion and convection regions, improving the uniformity of the electrolyte and surface smoothness. Compared with a magnetic field parallel to the electric field, a perpendicular magnetic field has more improvement in machining performance. Furthermore, combined perpendicular and parallel magnetic fields of 0.1 T increase cavity depth by 47.91%, the MRR by 30.88%, and reduced surface roughness Ra from 0.364 to 0.298 μm, compared with the case without the magnetic field assistance. This research underscores the efficacy of magnetic field assistance in advancing the precision and sustainability of EJM for Zr-based amorphous alloys.