高压电化学抛光增材制造件基础机理解析与方法探索

表面粗糙度成为当下制约金属增材制造技术应用的主要因素之一。高压电化学抛光方法（约>100 V）不受材料硬度、刚度和形状限制，抛光后无表面损伤层、残余应力，是高质高效实现增材构件绿色抛光的理想手段之一，但高压电化学抛光理论和工艺方法仍缺乏研究。

本文针对高压电化学抛光过程，基于现象学方法系统研究了高压电化学的区间划分理论，揭示了高压电化学过程的声信号、光信号、电信号特征，区分开等离子体电解抛光和电解等离子体抛光两种抛光模式。

通过高压电化学阳极界面效应的可视化观测和过程传热分析，揭示了电解/沸腾共同作用下的气泡-气膜行为及其演变过程，构建了电解-沸腾共同作用下的气泡成核与生长模型。在此基础上，提出并开发了一种核态沸腾电化学整平（Nucleate Boiling Electrochemical Leveling, NBEL）的新方法，利用工件表面气泡对电化学溶解过程的屏蔽、调控和强化作用实现了大原始粗糙度（Ra＞10 μm）增材制造件的高效整平。

通过对等离子体-电化学耦合行为及其特性进行分析，明确了等离子体的产生条件和形成过程。进一步结合光谱诊断研究等离子体的演变规律和主要成分，讨论了高压电化学过程中的等离子体物理化学特性及其对抛光结果影响。

针对增材制造件的表面特点，提出分步式高压电化学抛光方法。通过电压和电解液温度调控，使核态沸腾电化学整平、等离子体电解抛光和电解等离子体抛光三种模式原位融合，实现了增材制造件大粗糙度表面的高效高质抛光。

研究成果可以支撑增材制造产业发展，为高压电化学研究提供理论依据和技术积累。

Surface roughness has become one of the main factors restricting the application of metal additive manufacturing technology. The high-voltage electrochemical polishing (HEP) method (about >100 V) is free of damage and stress regardless of material hardness, stiffness, and shape, making it one ideal approach to achieving high-quality polishing of additive components. However, the theory and basic laws are still unclear.

Aiming at the HEP process, the regime division theory of high-voltage electrochemistry was systematically studied based on phenomenological method. And the characteristics of the acoustic signal, optical signal and V-A signal of the high-voltage electrochemical process were revealed. For the first time, two polishing modes of plasma electropolishing and electrolytic plasma polishing were distinguished.

Through visual observation of the high-voltage electrochemical anode interface reactions and the heat transfer analysis, the bubble-gas film behavior and evolution process under the combined effect of electrolysis and boiling were revealed, and the model of bubble nucleation and growth was established. On this basis, a new method of Nucleate Boiling Electrochemical Leveling (NBEL) was creatively proposed and developed, which utilizes the shielding, regulating and strengthening effects of bubbles on the surface of the workpiece to the electrochemical dissolution process. High-efficiency leveling of additively manufactured components with large original roughness (Ra>10 μm) was achieved.

By analyzing the coupling behaviour of electrochemical-plasma and its heat transfer condition, the generation conditions and formation process of plasma were clarified. Furthermore, the evolution law and main composition of the plasma were studied in combination with the optical spectral diagnosis. And the physical and chemical properties of the plasma in the high-voltage electrochemical process and their influence on the polishing results were clarified.

According to the surface characteristics of additive manufactured parts, a step-wise high-voltage electrochemical polishing method was proposed. Through the regulation of voltage and electrolyte temperature, the three modes of interface-boiling electrochemical leveling, plasma electropolishing, and electrolytic plasma polishing were in-situ integrated, realizing high-quality polishing of large roughness surfaces of additive manufactured parts.

The research results can support the development of the additive manufacturing industry and provide theoretical basis and technical accumulation for high-voltage electrochemistry research.

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