Hybrid laser-electrochemical (micro)machining of advanced materials

The ongoing shift towards high-end and functionality-oriented manufacturing has resulted in the emergence of hybrid manufacturing processes involving two or more process energies driven by demands for machining new materials while preserving surface/sub-surface integrity and intended functionality. In this context, this PhD research is fundamentally investigating a newer generation of hybrid machining known as hybrid laser-electrochemical micromachining which involves synergistic and coaxial application of green laser and electrochemical micromachining processes. While a prototype research setup to coaxially apply laser and electrochemical micromachining process has progressed, the fundamental removal mechanisms are not established; and very limited mechanistic knowledge is available in the prior state of the art. Therefore, this PhD project aims to tackle this at the 'manufacturing-science' level by generating (i) Newer insights into hybrid removal mechanisms (both micro and meso scale) while using an advanced material (bulk metallic glass) through hybridisation of a nanosecond pulsed green laser and microsecond pulsed electrochemical micromachining process (ii) Specific focus on analysing hybrid mechanisms in the absence of grain boundaries and non-crystalline nature (iii) In-depth fundamental analysis on the mechanisms of weakening of passivation layer during hybrid processing. The PhD research sits at the intersection of manufacturing, materials and electrochemistry fundamentals.