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

ZHOU Chuanqiang; QIAN Ning; DING Wenfeng; FU Yucan; SU Honghua

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

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

Precision and Ultra-precision Machining

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

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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.

Key words

aerospace alloys / complex structure surfaces / surface polishing / plasma electrolytic polishing / polishing mechanisms / process parameters

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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

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Funding

National Natural Science Foundation of China (52205476); Fundamental Research Funds for the Central Universities (NG2024008); Major Project of Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology (1005-ZAA20003-14); Innovation Capacity Building Program for Sci-Tech SMEs of Shandong (2025TSGCCZZB0886)