Investigation of electrolyte and auxiliary anode effects in Electrochemical Discharge Machining of equiatomic AlCrCuFeNi high-entropy alloy

Investigation of electrolyte and auxiliary anode effects in Electrochemical Discharge Machining of equiatomic AlCrCuFeNi high-entropy alloy | 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 Investigation of electrolyte and auxiliary anode effects in Electrochemical Discharge Machining of equiatomic AlCrCuFeNi high-entropy alloy SEKAR TAMILPERUVALATHAN, Suganaya Priyadarshini Ganesan, Prasanth Ponnusamy, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8894986/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 This study investigates the electrochemical discharge machining (ECDM) performance of a newly cast equiatomic AlCrCuFeNi high-entropy alloy, targeted for demanding applications like aerospace, nuclear, marine and defense components. The alloy was synthesized using vacuum induction melting and characterized using SEM, EDS and FTIR in order to confirm compositional uniformity and passive film formation. A sodium nitrate based electrolyte system (C1) was procedurally modified using borax (C2), sodium lauryl sulfate (SLS) (C3) and cetyltrimethylammonium bromide (CTAB) (C4) to analyze the influence of buffering and surfactant chemistry on gas film stability, material removal (MR) and tool wear (TW). A Taguchi L16 design integrated voltage, duty cycle, electrolyte type, auxiliary anode material and auxiliary anode position. The C1 electrolyte under 110 V and 70% duty cycle with copper auxiliary electrode, placed in right position to the workpiece achieved a maximum MR of 38 mg with controlled TW of 7 mg. Electrolyte chemistry emerged as the dominant factor for both MR (Δ = 17.42) and TW (Δ = 11.13). Grey Relational Analysis (GRA) validated the optimized condition, confirming a balanced enhancement of productivity and tool life. The proposed strategy offers a sustainable ECDM framework for machining advanced heat-entropy alloys. High-entropy alloy Electrochemical discharge machining Electrolyte engineering Surfactant-assisted machining Material removal Tool wear Grey relational analysis Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 08 Apr, 2026 Reviewers invited by journal 06 Apr, 2026 Editor assigned by journal 18 Feb, 2026 First submitted to journal 16 Feb, 2026 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. 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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-8894986","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":618244333,"identity":"38bf53ac-48d3-4200-9005-f212494e3b9b","order_by":0,"name":"SEKAR TAMILPERUVALATHAN","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA5ElEQVRIiWNgGAWjYDCCA1DC/njzAagQYwMBLcxQfWeOJTAwJJCk5YaPAVQLAcB3+/zhDx/O2OUzzuD5/OLnDwZ5/gbmtgf4tEieS2aTnHEj2bJZunebZU8Cg+GMA4ztBvi0GJxhZmPm+cBswCZzdpsx0GGMGxgY2yQIaGH+/OdDvQGPRM4zkBZ7YrQwSDPcOGwgIZHD/BioJZGgFskzzGaSPWeOGxjwHDNj7EmTSJ5xmIAWvjOMjz/8OFZtYMDeDGTY2Nj2t7c/w6sFGbABVQIRM7HqgYD5AwmKR8EoGAWjYAQBACbcSosjPcW4AAAAAElFTkSuQmCC","orcid":"https://orcid.org/0000-0001-9527-4976","institution":"Government College of Technology","correspondingAuthor":true,"prefix":"","firstName":"SEKAR","middleName":"","lastName":"TAMILPERUVALATHAN","suffix":""},{"id":618244334,"identity":"f977e167-640d-4c82-ac8d-06f34fa1d7b7","order_by":1,"name":"Suganaya Priyadarshini Ganesan","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Suganaya","middleName":"Priyadarshini","lastName":"Ganesan","suffix":""},{"id":618244335,"identity":"9c57e8d1-6577-4db0-bbde-328f46339ba9","order_by":2,"name":"Prasanth Ponnusamy","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Prasanth","middleName":"","lastName":"Ponnusamy","suffix":""},{"id":618244336,"identity":"79646f5e-926f-408c-8ff3-5d11e10c9e2c","order_by":3,"name":"Bharath Pandian","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Bharath","middleName":"","lastName":"Pandian","suffix":""}],"badges":[],"createdAt":"2026-02-16 17:01:40","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-8894986/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-8894986/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":107479249,"identity":"dba7f945-71b8-4e16-aaf8-c023b468ffb5","added_by":"auto","created_at":"2026-04-22 01:21:11","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":557056,"visible":true,"origin":"","legend":"","description":"","filename":"ECDMofequiatomicAlCrCuFeNihighentropyalloy.pdf","url":"https://assets-eu.researchsquare.com/files/rs-8894986/v1_covered_0ba7bc3b-5146-49b7-8aab-1e0faae6d99c.pdf"}],"financialInterests":"","formattedTitle":"Investigation of electrolyte and auxiliary anode effects in Electrochemical Discharge Machining of equiatomic AlCrCuFeNi high-entropy alloy","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":"High-entropy alloy, Electrochemical discharge machining, Electrolyte engineering, Surfactant-assisted machining, Material removal, Tool wear, Grey relational analysis","lastPublishedDoi":"10.21203/rs.3.rs-8894986/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8894986/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study investigates the electrochemical discharge machining (ECDM) performance of a newly cast equiatomic AlCrCuFeNi high-entropy alloy, targeted for demanding applications like aerospace, nuclear, marine and defense components. The alloy was synthesized using vacuum induction melting and characterized using SEM, EDS and FTIR in order to confirm compositional uniformity and passive film formation. A sodium nitrate based electrolyte system (C1) was procedurally modified using borax (C2), sodium lauryl sulfate (SLS) (C3) and cetyltrimethylammonium bromide (CTAB) (C4) to analyze the influence of buffering and surfactant chemistry on gas film stability, material removal (MR) and tool wear (TW). A Taguchi L16 design integrated voltage, duty cycle, electrolyte type, auxiliary anode material and auxiliary anode position. The C1 electrolyte under 110 V and 70% duty cycle with copper auxiliary electrode, placed in right position to the workpiece achieved a maximum MR of 38 mg with controlled TW of 7 mg. Electrolyte chemistry emerged as the dominant factor for both MR (Δ\u0026thinsp;=\u0026thinsp;17.42) and TW (Δ\u0026thinsp;=\u0026thinsp;11.13). Grey Relational Analysis (GRA) validated the optimized condition, confirming a balanced enhancement of productivity and tool life. 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