Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation

doi:10.1007/s40436-024-00531-y

Abstract

Abstract: To enhance the performance of aero-engines, honeycomb seals are commonly used between the stator and rotor to reduce leakage and improve mechanical efficiency. Because of the thin-walled and densely distributed honeycomb holes, machining defects are prone to occur during manufacturing. Electrochemical grinding (ECG) can minimize machining deformation because it is a hybrid process involving electrochemical dissolution and mechanical grinding. However, electrolysis will generate excessive corrosion on the honeycomb surface, which affects the sealing capability and operational performance. In this study, an ECG method using an electrolyte of 10% (mass fraction) NaCl is proposed to machine the inner cylindrical surface of the honeycomb seal, and an eco-friendly inhibitor, sodium dodecylbenzene sulfonate (SDBS), is introduced to the electrolyte to inhibit corrosion of the honeycomb structure. A theoretical relationship between the voltage and feed rate during ECG is proposed, and the excessive corrosion of the honeycomb single-foiled segment is used as a measurement of the impact of electrolysis. The corrosion inhibition efficiency of SDBS on the honeycomb material in 10% (mass fraction) NaCl solution is evaluated through electrochemical tests, and the suitable feed rate and optimal concentration of SDBS are determined through ECG experiments. Additionally, the corrosion inhibition effect of SDBS is validated through four groups of comparative experiments. The results indicate that the inhibition efficiency of SDBS increases with increasing concentration, reaching the maximum of 73.44%. The optimal SDBS mass fraction is determined to be 0.06%. The comparative experiments show that excessive corrosion is reduced by more than 40%. This establishes ECG as an effective and environmentally friendly processing method for honeycomb seals by incorporating SDBS into a 10% (mass fraction) NaCl solution.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00531-y

Key words: Electrochemical grinding (ECG), Honeycomb seal, Sodium dodecylbenzene sulfonate (SDBS), Eco-friendly inhibitor

Jin-Hao Wang, Lu Wang, Han-Song Li, Ning-Song Qu. Electrochemical grinding of honeycomb seals using sodium dodecylbenzene sulfonate as an eco-friendly inhibitor: machining principle and performance evaluation[J]. Advances in Manufacturing, 2025, 13(1): 229-244.

TrendMD

References

[1] Jeyakrishnan PR, Chockalingam KK, Narayanasamy R (2013) Studies on buckling behavior of honeycomb sandwich panel. Int J Adv Manuf Technol 65:803-815
[2] Childs D, Elrod D, Hale K (1989) Annular honeycomb seals: test results for leakage and rotordynamic coefficients; comparisons to labyrinth and smooth configurations. J Tribol 111:293-300
[3] Wang YQ, Gan YQ, Liu HB et al (2020) Surface quality improvement in machining an aluminum honeycomb by ice fixation. Chin J Mech Eng 33(1):1-8
[4] Sun JS, Dong ZG, Wang XP et al (2020) Simulation and experimental study of ultrasonic cutting for aluminum honeycomb by disc cutter. Ultrasonics 103:106102. https://doi.org/10.1016/j.ultras.2020.106102
[5] Tian YB, Zhong ZW, Rawat R (2015) Comparative study on grinding of thin-walled and honeycomb-structured components with two CBN wheels. Int J Adv Manuf Technol 81:1097-1108
[6] Gao J, Ma XF, Liu QY (2012) Experimental study of electrical discharge grinding honeycomb tori. Adv Mater Res 468:924-927
[7] Ge YC, Zhu ZW, Zhu YW (2019) Electrochemical deep grinding of cast nickel-base superalloys. J Manuf Process 47:291-296
[8] Fan KN, Jin ZJ, Zhu XL (2022) Investigation on electrochemical grinding (ECG) of pure iron material. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-021-08335-1
[9] Shu T, Liu Y, Wang K et al (2022) Ultrasonic vibration-aided electrochemical drill-grinding of SLM-printed Hastelloy X based on analysis of its electrochemical behavior. Electrochem Commun 135:107208. https://doi.org/10.1016/j.elecom.2022.107208
[10] Li SS, Wu YB, Nomura M et al (2018) Fundamental machining characteristics of ultrasonic-assisted electrochemical grinding of Ti-6Al-4V. J Manuf Sci Ent 140(7):071009. https://doi.org/10.1115/1.4039855
[11] Haberstich M (1968) Electrochemical grinding as applied to jet engine overhaul. SAE Trans 77(4):2630-2640
[12] Roebuck AH, Gant PL, Riggs OL et al (1957) Corrosion and adsorption studies using sulfonate inhibitors. Corrosion 13(11):55-60
[13] Qian S, Cheng YF (2019) Synergism of imidazoline and sodium dodecylbenzenesulphonate inhibitors on corrosion inhibition of X52 carbon steel in CO₂-saturated chloride solutions. J Mol Liq 294:111674. https://doi.org/10.1016/j.molliq.2019.111674
[14] Zhang YY, Xu K, Liu B et al (2022) Effects of different metal corrosion inhibitors on hydrogen suppression and film formation with Mg-Zn alloy dust in NaCl solutions. Int J Hydrog Energy 47(67):29172-29183
[15] Hasegawa Y, Hanasaki S, Touge M et al (1988) Electromechanical grinding at high work feed rate. Precis Eng 10(2):71-79
[16] Noble CF, Davies BJ (1983) Electro-mechanical action in peripheral electrochemical grinding. CIRP Ann 32(1):123-127
[17] Kong HH, Qu NS, Kong WJ (2022) Multiphysics simulation and experimental investigation on jet electrochemical milling of Ti-6Al-4V alloy. J Electrochem Soc 169(9):093502. https://doi.org/10.1149/1945-7111/ac8cb8
[18] Kubota M, Tamura Y, Inoue M (1980) Cutting ability of electrode-wheels used in electrochemical grinding. J Jpn Soc Electr Mach Eng 14(27):41-49
[19] Wang YD, Xu ZY, Zhang A (2019) Electrochemical dissolution behavior of Ti-45Al-2Mn-2Nb+ 0.8 vol% TiB₂ XD alloy in NaCl and NaNO₃ solutions. Corros Sci 157:357-369
[20] Finšgar M, Jackson J (2014) Application of corrosion inhibitors for steels in acidic media for the oil and gas industry: a review. Corros Sci 86:17-41
[21] Qiang YJ, Zhang ST, Xu SY et al (2015) The effect of 5-nitroindazole as an inhibitor for the corrosion of copper in a 3.0% NaCl solution. Rsc Adv 5(78):63866-63873
[22] Wang ZQ, Gong YL, Jing C et al (2016) Synthesis of dibenzotriazole derivatives bearing alkylene linkers as corrosion inhibitors for copper in sodium chloride solution: a new thought for the design of organic inhibitors. Corros Sci 113:64-77
[23] Qiang YJ, Zhang ST, Xu SY et al (2016) Experimental and theoretical studies on the corrosion inhibition of copper by two indazole derivatives in 3.0% NaCl solution. J Colloid Interf Sci 472:52-59
[24] Gao CP, Qu NS, Ding B et al (2019) An insight into cathodic reactions during wire electrochemical micromachining in aqueous hydrochloric acid solution. Electrochim Acta 295:67-74
[25] Zhao RX, Xu WD, Yu Q et al (2020) Synergistic effect of SAMs of S-containing amino acids and surfactant on corrosion inhibition of 316L stainless steel in 0.5 M NaCl solution. J Mol Liq 318:114322. https://doi.org/10.1016/j.molliq.2020.114322
[26] Fernandes CM, Alvarez LX, dos Santos NE et al (2019) Green synthesis of 1-benzyl-4-phenyl-1H-1, 2, 3-triazole, its application as corrosion inhibitor for mild steel in acidic medium and new approach of classical electrochemical analyses. Corros Sci 149:185-194
[27] Kong DC, Ni XQ, Dong CF et al (2019) Anisotropic response in mechanical and corrosion properties of Hastelloy X fabricated by selective laser melting. Constr Build Mater 221:720-729
[28] Liu J, Wang DP, Gao LX et al (2016) Synergism between cerium nitrate and sodium dodecylbenzenesulfonate on corrosion of AA5052 aluminium alloy in 3 wt.% NaCl solution. Appl Surf Sci 389:369-377
[29] He X, Wang L, Kong DC et al (2023) Recrystallization effect on surface passivation of Hastelloy X alloy fabricated by laser powder bed fusion. J Mater Sci Technol 163:245-258
[30] Growcock FB, Jasinski RJ (1989) Time-resolved impedance spectroscopy of mild steel in concentrated hydrochloric acid. J Electrochem Soc 136(8):2310. https://doi.org/10.1149/1.2097847
[31] Zhao TL, Wang ZX, Feng YJ et al (2022) Synergistic corrosion inhibition of sodium phosphate and sodium dodecyl sulphate on magnesium alloy AZ91 in 3.5 wt% NaCl solution. Mater Today Commun 31:103568. https://doi.org/10.1016/j.mtcomm.2022.103568
[32] Qiang YJ, Zhang ST, Guo L et al (2017) Sodium dodecyl benzene sulfonate as a sustainable inhibitor for zinc corrosion in 26% NH₄Cl solution. J Clean Prod 152:17-25
[33] Xu Y, Tan BM, Hu LJ et al (2020) Synergetic effect of 5-methyl-1H-benzotriazole and sodium dodecyl benzene sulfonate on CMP performance of ruthenium barrier layer in KIO₄-based slurry. Ecs J Solid State Sc 9(10):104005. https://doi.org/10.1149/2162-8777/abbea0
[34] Palazzesi F, Calvaresi M, Zerbetto F (2011) A molecular dynamics investigation of structure and dynamics of SDS and SDBS micelles. Soft Matter 7(19):9148-9156
[35] Chen Y, Wang XD, Lai T et al (2022) Sodium dodecylbenzene sulfonate film absorbed on magnesium alloy surface: an electrochemical, SKPFM, and molecular dynamics study. J Mol Liq 357:119095. https://doi.org/10.1016/j.molliq.2022.119095
[36] Chen JL, He JX, Li LJ (2021) Spectroscopic insight into the role of SDBS on the interface evolution of Mg in NaCl corrosive medium. Corros Sci 182:109215. https://doi.org/10.1016/j.corsci.2020.109215