Study on Vertical Non-Uniformity of Plasma Electrolytic Polishing

Aiming at non-uniformity in the vertical direction in the polishing effect on stainless steel after plasma electrolytic polishing (PEP), this paper took 304 L stainless steel as the research object. Under an ammonium sulfate electrolyte system with a mass fraction of 2.5 wt%, PEP was carried out utilizing different placement methods for the anode and electrolyte temperatures, and the causes of non-uniformity in the polishing process were explored. Experimental results demonstrate that the vertical polishing inhomogeneity originates from the upward movement of unruptured bubbles at the sample bottom. Under the combined effects of electrolyte internal pressure and bubble buoyancy, a vapor-gas envelope (VGE) featuring a thick upper part and thin lower part forms near the sample surface. This enhances plasma-related physicochemical reactions at the sample bottom and consequently raises the polishing rate. The vertical polishing unevenness can be alleviated by adjusting the electrolyte temperature. Non-uniformity could be improved by controlling the temperature of the electrolyte. Compared with the result at 95 °C, the maximum dimensional variation in each region on the sample at 75 °C was reduced by 36% because a VGE with more uniform thickness was formed, and a properly oxidized sparse layer helped protect the substrate from ablation and over-polishing. In addition, the removal rate of elements on the surface of stainless steel is affected by its activity due to the oxidation reaction. The high removal amount in the bottom region caused a trend of increasing Cr and decreasing Fe content percentages from the top to the bottom on the stainless-steel surface. However, the oxidation removal rate of elements is extremely fast due to the high temperature of the ionization center and strong electric field; therefore, the content percentage of each element on the surface is little changed after polishing.