Corrosion processing is an effective way to solve difficult machining of titanium alloy. It can be applied for reducing weight, machining complex shape and fine structure. In this paper, the effects of the bath constituents and operation conditions on corrosion processing rate and surface quality for Ti-6Al-4V were investigated. Corrosion processing rate depends upon hydrofluoric acid concentration, the volume ratio of nitric acid to hydrofluoric acid, temperature. Nitric acid can promote the surface passivation and reduce surface roughness. The surfactant plays a dual role of surface finish improvement and acid fog suppression. During the period of processing, oxide film on the surface is dissolved initially, and there is the faster processing rate. Surface passivation occurs with the extension of time, decreasing processing rate. Finally corrosion processing rate trends to be stable when the growth of passive film and dissolution of the substrate achieve dynamic balance.

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