Deep Cryogenic Treatment of Various Electrodes for Enhanced Electrochemical Machining Performance of Wire Arc Additive Manufactured Stainless Steel

This study aimed to evaluate the effect of deep‐cryogenic treatment (DCT) on the properties of electrodes, including corrosion resistance, electrochemical stability, and electrochemical machining (ECM) performance, in wire arc‐produced SS309. Deposition parameters such as voltage (8, 10, and 12 V), electrolyte concentration (20, 30, and 40 g/l), duty cycle (45, 55, and 65%), and pulse frequencies (40, 50, and 60 Hz) are varied to examine ECM performance. The electrical conductivities of BeCu and SS304 increased by 37.88% and 83.31%, respectively, indicating easier ion transfer and better machining capabilities. The corrosion resistance of DCT‐modified electrodes is further improved, with corrosion current densities decreasing by 26.1% for BeCu and 43.5% for SS304. Electrochemical stability tests showed that DCT enhanced the stability of both electrodes, evidenced by a slight shift toward more positive corrosion potentials and lower current responses. In terms of ECM performance, compared to untreated electrodes, DCT‐treated samples achieved higher material removal rates, improved circularity, and reduced conicity, indicating better geometric accuracy and surface quality. DCT‐treated SS304 electrodes exhibited the best performance, with increased machining stability and precision. This research demonstrates that DCT is a promising method for improving the ECM process, especially in high‐precision fields such as aerospace, automotive, and biomedical manufacturing.