To provide an electrode wire for electrical discharge machining including β-brass and γ-brass arranged on an outer peripheral surface of a core and a method of manufacturing the electrode wire, capable of enhancing wire connection performance and cutting down manufacturing cost while trying to increase a processing speed.

The electrode wire for electrical discharge machining according to this invention comprises: an external layer including β-brass and γ-brass; and a core having an undulating shape formed at a boundary surface with the external layer. The β-brass and the γ-brass are arranged densely and sparsely at the boundary surface of the undulating shape. The method of manufacturing an electrode wire for electrical discharge machining according to this invention comprises: a thermal processing step of executing thermal process on a base material under a predetermined thermal processing condition, the base material having a core with a zinc-coated surface; and a wire drawing step of drawing a base wire under a predetermined wire drawing condition provided with β-brass and γ-brass formed at the surface of the core by the thermal process to make the γ-brass reach the core, thereby forming a boundary surface of the core with an external layer into an undulating shape.

To provide an electrode wire for electrical discharge machining including β-brass and γ-brass arranged on an outer peripheral surface of a core and a method of manufacturing the electrode wire, capable of enhancing wire connection performance and cutting down manufacturing cost while trying to increase a processing speed.

The electrode wire for electrical discharge machining according to this invention comprises: an external layer including β-brass and γ-brass; and a core having an undulating shape formed at a boundary surface with the external layer. The β-brass and the γ-brass are arranged densely and sparsely at the boundary surface of the undulating shape. The method of manufacturing an electrode wire for electrical discharge machining according to this invention comprises: a thermal processing step of executing thermal process on a base material under a predetermined thermal processing condition, the base material having a core with a zinc-coated surface; and a wire drawing step of drawing a base wire under a predetermined wire drawing condition provided with β-brass and γ-brass formed at the surface of the core by the thermal process to make the γ-brass reach the core, thereby forming a boundary surface of the core with an external layer into an undulating shape.

A system for forming features within composite components includes a tubular electrode extending along a longitudinal direction from a proximal end to a distal end. The distal end is, in turn, configured to be positioned relative to a machining surface of the composite component such that a spark gap is defined between the distal end and the machining surface. Furthermore, the tubular electrode further extends in a radial direction between an inner surface and an outer surface, with the inner surface defining a central passage configured to supply a dielectric fluid to the machining surface. The outer surface of the tubular electrode includes at least one a channel defined therein or a non-circular cross-sectional shape.

An electrode includes a metallic electrode body that has a surface region that is enriched in at least one of aluminum or chromium. The aluminum and/or chromium that is vaporized from the surface region suppresses vaporization loss of aluminum or chromium from the machined surface of the metallic workpiece during electric discharge machining.

An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

An additive manufactured workpiece includes one or more cavities having an inner surface. A dielectric interface is formed in the cavity, and conforms to the inner surface. The additive manufactured workpiece further includes an in-situ electrode in the cavities. The dielectric interface is interposed between the in-situ electrode and the inner surface of the workpiece.

A method of improving an internal surface topography of a manufactured workpiece includes filling a workpiece with an electrically conductive magnetorheological (MR) fluid. The workpiece includes at least one internal feature having an inner surface with at least one irregularity. The method further includes converting the MR fluid into a rigid MR material, applying a voltage to the rigid MR material, and ablating the inner surface in response to the voltage to remove the at least one irregularity.

A method of improving an internal surface topography of a manufactured workpiece includes filling a workpiece with an electrically conductive magnetorheological (MR) fluid. The workpiece includes at least one internal feature having an inner surface with at least one irregularity. The method further includes converting the MR fluid into a rigid MR material, applying a voltage to the rigid MR material, and ablating the inner surface in response to the voltage to remove the at least one irregularity.

An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.

An electrode applied in electro-machining processes, where the electrode includes a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.