Ti-6Al-4V is widely used in aerospace, biomedical applications and in many corrosive environments. However, titanium alloy has low hardness and poor wear resistance. This paper introduces a machining method of SiC abrasive-mixed electrical discharge machining (EDM) with magnetic stirring. Structural features and chemical composition were analyzed by scanning electron microscope (SEM) and X-ray diffraction (XRD). Micro-hardness distribution on the cross section was measured with an FM800 micro-hardness tester. The influence of pulse width and pulse peak current on the formation of the surface hardening layer is analyzed. The results show that a continuous strengthened layer was formed during the SiC abrasive-mixed EDM process. The hardness of the formed layer was significantly improved because of the formation of TiC and TiSi₂ phases on the machined surface. With the increase of pulse width, the thickness of the strengthened layer increases and the quality becomes better.

Nickel–titanium (Ni-Ti) alloy has been selected as stent material given its good biocompatibility. In this study, experimental research on this material was conducted using magnetic field-assisted electrical discharge machining (EDM). The surface topography of the machined workpiece was analyzed with a scanning electron microscope (SEM). Hydrophobicity was measured by using an optical contact angle measuring instrument. The roughness values of different positions on the surface were measured using a TR200 roughness instrument. Results showed that the composite structure of solidification bulge–crater–pore–particle can be prepared on the surface of the Ni-Ti alloy through magnetic mixed EDM using suitable processing parameters. Moreover, the contact angle of the surface reaches 138.2°.

Quartz glass shows superior physicochemical properties and is used in modern high technology. Due to its hard and brittle characteristics, traditional polishing slurry mostly uses strong acid, strong alkali, and potent corrosive additives, which cause environmental pollution. Furthermore, the degree of damage reduces service performance of the parts due to the excessive corrosion. Therefore, a novel quartz glass green and efficient non-damaging chemical mechanical polishing slurry was developed, consisting of cerium oxide (CeO₂), Lanthanum oxyfluoride (LaOF), potassium pyrophosphate (K₄P₂O₇), sodium N-lauroyl sarcosinate (SNLS), and sodium polyacrylate (PAAS). Among them, LaOF abrasive showed hexahedral morphology, which increased the cutting sites and uniformed the load. The polishing slurry was maintained by two anionic dispersants, namely SNLS and PAAS, to maintain the suspension stability of the slurry, which makes the abrasive in the slurry have a more uniform particle size and a smoother sample surface after polishing. After the orthogonal test, a surface roughness (S_a) of 0.23 nm was obtained in the range of 50 × 50 μm², which was lower than the current industry rating of 0.9 nm, and obtained a material removal rate (MRR) of 530.52 nm/min.

Polycrystalline diamond (PCD) is widely used for its excellent properties but difficult to be processed by traditional machining methods. Electrical discharge machining (EDM) is regarded as an important method to machine PCD because of its non-contact nature. In this study, copper-nickel (Cu-Ni) electrode was prepared by electrodeposition and used to machine PCD. The machining characteristics of PCD including surface morphology, material removal rate (MRR) and surface roughness (SR) were studied in detail. Results show that the surfaces processed by Cu-Ni electrode have a larger radius but shallow craters and less cracks than that by Cu electrode. The MRR of PCD by Cu-Ni electrode is 252% higher than that by Cu electrode, and the SR is 18% lower than that by Cu electrode after processing at low parameter value while they are 6% and 15% at high parameter value, respectively. The result indicates that graphitization of diamond dominates the removal process when processing by Cu-Ni electrode; however, when processing by Cu electrode, the principal cause of the diamond exfoliation was the fusion of the cobalt binder and explosion. This research provides an essential experimental basis for designing technics of precision and highly efficient electrical discharge machining PCD tools.

Cu-SiC composite electrodes composed of both a Cu matrix and dispersed inert SiC particles were fabricated for electrical discharge machining (EDM) using the ultrasonic-aided electrodeposition technique. The influence of ultrasonic power on the surface morphology, content of SiC particles, and EDM wear rate of the fabricated Cu-SiC composite electrode were investigated. Results show that the incorporation of SiC particles into the composite electrode was enhanced and that the uniformity of particle distribution in the Cu matrix improved when the ultrasonic dispersion was initiated during electrodeposition. The composite that was generated at low ultrasonic power contained more SiC than that produced at high ultrasonic power. Moreover, the Cu-SiC electrode fabricated at low ultrasonic power displayed the least erosion wear during EDM.