Effect of discharge thermal action in ECDM on electrochemical behaviours of matrix material and its recast layer in glycol-based solution

The interaction between thermal and electrochemical corrosion in the ECDM process remains unclear. This study clarifies the effect of discharge thermal action on electrochemical corrosion. Real-time temperature curves indicate that the solution temperature in the electrochemical corrosion zone increased significantly due to discharge thermal action. The corrosion resistance of the recast layer’s passive film is superior to that of the matrix due to the enrichment of Cr₂O₃. As the electrolyte temperature rises, the passive film thickens but shows lower polarization resistances and poorer corrosion resistance due to a loose and weak structure. The matrix material and its recast layer dissolved uniformly, resulting in a considerably flat surface in a glycol-based solution, with enhanced levelling efficiency due to discharge thermal action.