Journal Article

Electrochemical Machining of Highly Strain-Hardenable High-Entropy FeMnCrCoSi Alloy: Role of Passivation and Selective Dissolution

Raja, Krishnan, Balakrishnan, Kavindan, Charit, Indrajit, Kumar, Kundan

2025

Overview

Fe42Mn28Cr15Co10Si5 is a highly strain-hardenable high-entropy alloy (HEA) that is challenging to machine with traditional metal cutting tools. The electrochemical behavior of this HEA was examined in nitrate- and chloride-based electrolytes to understand the electrochemical machining (ECM) process. Potentiodynamic and potentiostatic tests were conducted on this alloy in 1 M and 2.35 M NaNO3 solutions, with and without additions of 0.01 M nitric acid and 0.01 M citric acid. A 20% NaCl solution was also tested as an electrolyte. Nitrate solutions caused passivation of the HEA, while no passivation was observed in chloride solutions. Surface analysis with X-ray photoelectron spectrometry (XPS) indicated that adding citric acid helped reduce surface passivation. The Faradaic efficiency of ECM increased with higher applied voltage. The chloride solution showed higher Faradaic efficiency than nitrate-based solutions. Specifically, the Faradaic efficiency of 20% NaCl at 10 V is 57.4%, compared to 21.9% for 20% NaNO3 + 0.01 M citric acid at 10 V. Electrochemical parameters, including anodic and cathodic exchange current densities, Tafel slopes, and corrosion current densities, were calculated from the experimental data. The corrosion current densities in the 20% nitrate solutions ranged from 2.35 to 3.2 × 10−5 A/cm2, while the 20% chloride solution had a lower corrosion rate at 1.45 × 10−5 A/cm2. These electrochemical parameters can help predict the dissolution behavior of the HEA in nitrate and chloride solutions and aid in optimizing the ECM process.

• Publisher: MDPI AG
• Subject: Alloys / Analysis / Citric acid / Corrosion and anti-corrosives / Corrosion currents / Corrosion rate / Corrosion resistance / Current density / Cutting tools / Deformation / Dissolution / Efficiency / Electrochemical analysis / Electrochemical machining / Electrochemical reactions / Electrolytes / Entropy / Gas turbine engines / Grain size / Hardenability / High entropy alloys / Hot rolling / Machining / Metal cutting / Metalworking machinery / Nitric acid / Parameters / Passivity / Photoelectrons / Silicon / Sodium chloride / Sodium nitrates / Specialty metals industry / Stainless steel / Strain hardening / Surface analysis (chemical) / X ray photoelectron spectroscopy