Analysis of Multi-Physics Coupling of Small Holes in GH4169 Alloy by Electrolytic Processing of Tube Electrodes

This paper presents a simulation and experimental study of the structure of small holes in GH4169 alloy electrolytic ally processed by tube electrodes with different characteristic power sources. It analyzes the multi-physical field coupling relationship of flow, temperature, and electric fields within the interstitial space. The results indicate that the tube electrode electrolytic processing of the GH4169 alloy small hole structure with a pulsed power supply has more uniform temperature and current density distribution within the gap, which is beneficial to the processing accuracy and smoothness of the small hole structure. Meanwhile, SEM was used to analyze the microscopic morphology of the electrode end surface during short-circuiting, and it was concluded that as the processing continued, the electrode end surface gradually produced a non-metallic oxide layer, which destroyed the electric field of the gap and affected the processing stability. The use of high-frequency positive and negative pulse power can effectively avoid the generation of a non-metallic oxide layer. Through the combination of simulation analysis and experimental verification, it is concluded that increasing electrolyte pressure in stages can effectively improve machining accuracy and stability. The interstitial current increases as the feed rate of the tool electrode increases, and the diameter of the machined small hole decreases as it increases.