面向航空航天合金复杂结构的等离子电解抛光技术研究现状及展望

周传强; 钱宁; 丁文锋; 傅玉灿; 苏宏华

doi:10.16490/j.cnki.issn.1001-3660.2025.20.012

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表面技术 ›› 2025, Vol. 54 ›› Issue (20) : 155-181. DOI: 10.16490/j.cnki.issn.1001-3660.2025.20.012

精密与超精密加工

面向航空航天合金复杂结构的等离子电解抛光技术研究现状及展望

周传强^1,2, 钱宁^2,*, 丁文锋², 傅玉灿², 苏宏华²

作者信息 +

Research Status and Prospects of Plasma Electrolytic Polishing Technology for Complex Aerospace Alloy Structures

ZHOU Chuanqiang^1,2, QIAN Ning^2,*, DING Wenfeng², FU Yucan², SU Honghua²

Author information +

文章历史 +

摘要

随着航空航天领域对零件表面质量和结构复杂度要求的不断提高,复杂结构合金表面高效精密抛光技术的发展受到广泛关注。系统综述了当前复杂结构表面抛光技术的研究进展,涵盖了传统机械抛光、磨粒流抛光、磁流变抛光、激光束与电子束等能量束抛光,以及电化学抛光等典型方法,分析了各类技术在加工效率、适应性及表面质量方面的优势与局限性。随后,重点分析了等离子电解抛光的材料去除及表面平滑机制。结合近年来的研究进展,归纳了等离子电解抛光的新方法;总结了关键工艺参数及其对表面质量的影响规律;介绍了等离子电解抛光技术在不同合金材料及复杂结构件表面抛光中的应用效果。最后,对合金复杂结构表面抛光技术进行了总结。特别地,指出当前等离子电解抛光为代表的高效精密抛光技术在复杂结构加工中的发展瓶颈,提出未来研究应聚焦于多物理场耦合机制解析、智能化装备开发及绿色可控工艺构建,以推动该技术在航空航天乃至生物医疗和精密模具等领域的工程化应用。

Abstract

With increasing demands for surface quality, dimensional accuracy, and structural complexity of components in the aerospace sector, efficient and precision polishing technology for complex-structured alloy surfaces has gradually become a key step in manufacturing processes. This review outlines current research progress in polishing technologies for complex surfaces of aerospace alloys. While traditional polishing techniques offer advantages such as process simplicity and wide applicability, they still face common challenges when balancing the dual objectives of "high efficiency" and "high precision”. Based on a comprehensive evaluation on the strengths and limitations of various methods, special emphasis is placed on Plasma Electrolytic Polishing (PEP), an emerging metal surface polishing technology.
PEP is recognized as an efficient, environmentally friendly, and cost-effective metal surface polishing process, which is particularly suitable for polishing workpieces with complex structures, where it demonstrates unique advantages. Drawing on domestic and international research, the material removal mechanisms of PEP are elaborated, and strategies for achieving efficient and precision polishing are summarized. Regarding process parameters, the influence of key factors such as voltage, current density, electrolyte composition, temperature, and time on surface quality is systematically reviewed. Finally, the development of polishing technologies for complex-structured alloy surfaces is summarized, with particular attention to the remaining bottlenecks in the engineering application of efficient and precision polishing methods represented by PEP.
In terms of the polishing mechanism, PEP operates through the formation of a plasma discharge layer within the vapour gaseous envelope, where synergistic effects of electrochemical removal and physical impact lead to efficient elimination of surface asperities, thereby achieving surface smoothing. The material removal mechanism involves not only anodic dissolution and formation-removal of oxide films but also bubble dynamics, localized plasma micro-discharges, and transient micro-scale erosion under high temperature and pressure. Recent studies further reveal the decisive role of dynamic vapor envelope oscillations in polishing uniformity and surface quality, providing new theoretical support for mechanistic investigations.
Regarding polishing strategies, spray-type PEP combines directional electrolyte flushing with plasma discharge, reducing power supply requirements and enabling controlled polishing of localized areas. This approach expands its application to additive-manufactured components and complex structural parts. Methods such as vibration-assisted polishing can enhance material removal rate and surface consistency by regulating electrolyte flow and bubble dynamics. The introduction of pulsed power waveforms significantly alleviates the conflict between removal rate and surface quality, achieving integrated processing that combines high efficiency with superior surface integrity.
Process parameters including electrolyte composition, concentration, temperature, voltage, and polishing duration have direct and critical effects on the final polishing outcome. Different metal materials require tailored electrolyte formulations, while variations in concentration and temperature directly influence discharge stability and result in different surface quality.
As fundamental research continues to deepen and improve, PEP technology has made progress in understanding polishing mechanisms, developing process methods, and optimizing parameters. However, key technical challenges remain in areas such as micro-discharge mechanisms, electrolyte system optimization, process parameter stability, and equipment integration. Future research should focus on elucidating microscopic mechanisms, developing advanced electrolyte systems, innovating equipment and methods, and optimizing process parameters, so as to promote the application of this technology in polishing complex aerospace structures.

导出引用

周传强, 钱宁, 丁文锋, 傅玉灿, 苏宏华. 面向航空航天合金复杂结构的等离子电解抛光技术研究现状及展望[J]. 表面技术. 2025, 54(20): 155-181 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.20.012

ZHOU Chuanqiang, QIAN Ning, DING Wenfeng, FU Yucan, SU Honghua. Research Status and Prospects of Plasma Electrolytic Polishing Technology for Complex Aerospace Alloy Structures[J]. Surface Technology. 2025, 54(20): 155-181 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.20.012

中图分类号： TH161

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