Understanding the erosion mechanism during abrasive waterjet machining is essential to manufacture parts with the desired dimensions, surface finish and mechanical properties. Numerous models^1–3exist to predict the effect of the process parameters on the profile of the waterjet footprint. In these models the material properties are either not explicitly considered or taken as homogeneous. In addition, the effect of the original microstructure as well as the microstructural changes during abrasive waterjet machining are usually ignored. Therefore there is a need for a model material with tunable grain size in order to gain better insights into the abrasive wear mechanisms of metals.

Electrodeposition of nickel allows to vary the grain structure and thereby the mechanical properties in a fast, reproducible and inexpensive way. Varying the grain size without changing the composition from nanocrystalline to microcrystalline is highly desirable to perform systematic study. In this poster Ni electrodeposition is used as a tool to study erosion mechanisms during abrasive waterjet milling. By milling trenches in nickel samples with different grain sizes, it was observed that the microstructure has little effect on the erosion rate. Microstructural and mechanical characterization revealed surface nanocrystallization in the microcrystalline nickel specimens due to severe plastic deformation. The surface being altered, the mechanical properties are changed and the erosion rate reduced.

 This study shows the potential for using metal electrodeposition to produce model materials to study engineering issues. The range of microstructure offered by electrodeposition enabled us to screen the effect of the microstructure during abrasive waterjet machining. Similar approach could be extended to other machining and finishing processes.

References

¹ J. Billingham, C.B. Miron, D. A. Axinte, and M.C. Kong, Int. J. Mach. Tools Manuf. 68, 30 (2013).

² S. Anwar, D. A. Axinte, and A. A. Becker, Proc. Inst. Mech. Eng. Part J J. Eng. Tribol. 225, 821 (2011).

³ P. Lozano Torrubia, D. A. Axinte, and J. Billingham, Int. J. Mach. Tools Manuf. 95, 39 (2015).