Study on Adaptive Electrochemical Discharge Machining of MicroHoles in TBC-coated Nickel-based Superalloys

Study on Adaptive Electrochemical Discharge Machining of MicroHoles in TBC-coated Nickel-based Superalloys | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Study on Adaptive Electrochemical Discharge Machining of MicroHoles in TBC-coated Nickel-based Superalloys Aocheng Zhou, Jingbao Zhang, Xiaotong Wang, Yang Liu, Yongfeng Guo This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8431752/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 4 You are reading this latest preprint version Abstract With increasing demand for high-temperature capability, thermal barrier coatings (TBCs) and film cooling techniques are widely applied to nickel-based superalloy turbine blades. In this study, electrochemical discharge machining (ECDM) was employed to drill micro-holes in TBC-coated superalloys, and the electrical parameters were adaptively adjusted for different materials. Based on the analysis of voltage and current waveforms during machining of different materials, two voltage thresholds were defined to detect short circuits and electrical discharges, enabling material identification and adaptive adjustment of processing parameters. The effects of supply voltage, pulse width, duty cycle, and NaOH electrolyte concentration on machining quality were investigated. In superalloy machining, a voltage-based feed control strategy was employed. Micro-hole taper and burr width were compared between long-pulse-width and short-pulse-width process across various parameters. Under the optimized parameters (pulse width 10 µs, duty cycle 0.5, supply voltage 60 V and 5 wt% NaOH electrolyte), the taper was 0.0044, the burr width 36 µm, and the recast layer thickness 23.9 µm. During the thermal barrier coatings (TBCs) machining stage, a pressure-feedback feed strategy was adopted. The analysis attributes entrance roundness defects and delamination primarily to secondary machining of the TBC induced by ablation during bond-coat processing. With optimized parameters (pulse width 15 ms, duty cycle 0.5), the entrance roundness error was effectively reduced to 19 µm. Compared with constant‑parameter machining, the adaptive parameter strategy achieved better roundness and mitigated delamination. Electrochemical discharge machining TBC-coated superalloys adaptive processing parameter optimization Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 18 Apr, 2026 Reviewers invited by journal 18 Apr, 2026 Editor assigned by journal 28 Dec, 2025 First submitted to journal 22 Dec, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8431752","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":625359766,"identity":"d86ea99f-d752-4b04-b664-d83fb4c13fff","order_by":0,"name":"Aocheng Zhou","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Aocheng","middleName":"","lastName":"Zhou","suffix":""},{"id":625359767,"identity":"051ea28a-3c07-471c-b48e-0a4e4590498b","order_by":1,"name":"Jingbao Zhang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Jingbao","middleName":"","lastName":"Zhang","suffix":""},{"id":625359768,"identity":"a65acccb-8c47-47ee-b262-83141af7fa35","order_by":2,"name":"Xiaotong Wang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Xiaotong","middleName":"","lastName":"Wang","suffix":""},{"id":625359769,"identity":"d54dda1f-a478-4a63-ba6e-0bf14c8b2f33","order_by":3,"name":"Yang Liu","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yang","middleName":"","lastName":"Liu","suffix":""},{"id":625359770,"identity":"387b7e35-ecd5-4f39-a41e-4f59ecf82526","order_by":4,"name":"Yongfeng Guo","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAuklEQVRIiWNgGAWjYLCCiooDPCBagngtZ84c4OEhTcvZtgMMxGuRj0g+JnFw3h0Zewbmg7d5GOzyCGoxvJGWJnFw2zOgw9iSrXkYkosJa5mRYyb9cdthoBYeM2kehgOJDcRokTg4B6SF/xtxWuQlQFoawLawEafFgOdZssWBY0Ath9mMLecYJBNhS3vywRsHag7bs7c3P7zxpsKOCFsOMLBAooMZzCWkHmRLAwPzByLUjYJRMApGwUgGAGpSOQPpfPnjAAAAAElFTkSuQmCC","orcid":"","institution":"Harbin Institute of Technology","correspondingAuthor":true,"prefix":"","firstName":"Yongfeng","middleName":"","lastName":"Guo","suffix":""}],"badges":[],"createdAt":"2025-12-23 08:18:03","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8431752/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8431752/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":108007229,"identity":"257ffe10-2c2e-4e58-bf43-5e490618701d","added_by":"auto","created_at":"2026-04-28 12:59:03","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1709101,"visible":true,"origin":"","legend":"","description":"","filename":"AdaptiveElectrochemicalDischargeMachining.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8431752/v1_covered_64f59c87-c79d-4b68-add5-4edbc3408a89.pdf"}],"financialInterests":"","formattedTitle":"Study on Adaptive Electrochemical Discharge Machining of MicroHoles in TBC-coated Nickel-based Superalloys","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Electrochemical discharge machining, TBC-coated superalloys, adaptive processing, parameter optimization","lastPublishedDoi":"10.21203/rs.3.rs-8431752/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8431752/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eWith increasing demand for high-temperature capability, thermal barrier coatings (TBCs) and film cooling techniques are widely applied to nickel-based superalloy turbine blades. In this study, electrochemical discharge machining (ECDM) was employed to drill micro-holes in TBC-coated superalloys, and the electrical parameters were adaptively adjusted for different materials. Based on the analysis of voltage and current waveforms during machining of different materials, two voltage thresholds were defined to detect short circuits and electrical discharges, enabling material identification and adaptive adjustment of processing parameters. The effects of supply voltage, pulse width, duty cycle, and NaOH electrolyte concentration on machining quality were investigated. In superalloy machining, a voltage-based feed control strategy was employed. Micro-hole taper and burr width were compared between long-pulse-width and short-pulse-width process across various parameters. Under the optimized parameters (pulse width 10 \u0026micro;s, duty cycle 0.5, supply voltage 60 V and 5 wt% NaOH electrolyte), the taper was 0.0044, the burr width 36 \u0026micro;m, and the recast layer thickness 23.9 \u0026micro;m. During the thermal barrier coatings (TBCs) machining stage, a pressure-feedback feed strategy was adopted. The analysis attributes entrance roundness defects and delamination primarily to secondary machining of the TBC induced by ablation during bond-coat processing. With optimized parameters (pulse width 15 ms, duty cycle 0.5), the entrance roundness error was effectively reduced to 19 \u0026micro;m. Compared with constant‑parameter machining, the adaptive parameter strategy achieved better roundness and mitigated delamination.\u003c/p\u003e","manuscriptTitle":"Study on Adaptive Electrochemical Discharge Machining of MicroHoles in TBC-coated Nickel-based Superalloys","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-04-27 12:50:05","doi":"10.21203/rs.3.rs-8431752/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2026-04-18T10:16:28+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-04-18T08:59:47+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-12-28T22:53:08+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-12-23T03:17:21+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"7a5583e8-3d3b-435b-8a73-bcb9bf6667f6","owner":[],"postedDate":"April 27th, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-04-27T12:50:06+00:00","versionOfRecord":[],"versionCreatedAt":"2026-04-27 12:50:05","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8431752","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8431752","identity":"rs-8431752","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}