Electrochemical Anodic Dissolution Characteristics and Polishing Behavior of Ti6Al4V Alloy Assisted by Magnetic Field

Electrical discharge wire cutting of Ti6Al4V alloy surfaces often results in recast layers, micro-cracks, and high roughness, which severely impairs service performance. To improve surface quality, this study introduces magnetic field-assisted electrochemical polishing. However, the influence of the magnetic field on electrolyte flow and anode surface current density distribution remains unclear due to the complexity of ion migration in electrochemical systems. To elucidate its mechanism, a coupled electric field-magnetic field-fluid flow model was constructed to simulate the flow behavior of the electrolyte and anodic current density distribution under the influence of a magnetic field. The results show that both fluid velocity and anodic surface current density increase with the strength of the magnetic field, particularly under a perpendicular magnetic field. Experimental results demonstrate that when a 0.2 T perpendicular magnetic field is applied, the polishing effect is optimal, with no significant defects on the Ti6Al4V alloy surface, reducing roughness from 3.445 μm before polishing to 0.521 μm, an 84.85% reduction. Meanwhile, the surface corrosion current density decreased from 8.82 × 10 –6 A·cm −2 to 2.53 × 10 –9 A·cm −2 , decreasing by three orders of magnitude, showing excellent corrosion resistance.