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EDM surface contamination.

EDM surface contamination.

EDM surface contamination.

(OP)
We have a Sodick AG55L plunge EDM that is being used to cut small (3 mm x 8 mm) rectangular thru-cutouts into 6061-T6 aluminum. The electrode being used is C145 high-tellurium copper.

We've been having problems with surface finish/scale; a dark gray scale is left after the EDM process, and it is very difficult to remove, even with an acid treatment.

So far, I've tried changing the toolpath (more/smaller passes), and the electrode area (reduced voltage) to reduce the scale.

One thing I've noticed is that there are quite a few bubbles in the dielectric fluid. Could this be the cause of our surface scale problems? Has anyone seen anything similar to this before?

Best,

Jacob

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