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 12V), electrolyte concen
tration (20, 30, and 40 g/l), duty cycle (45, 55, and 65%), and pulse frequencies
(40, 50, and 60Hz) 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, evi
denced by a slight shift toward more positive corrosion potentials and lower
current responses. In terms of ECM performance, compared to untreatedelectrodes, 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