The traditional finishing processes are incapable of producing required surface finish and other characteristics in difficult-to machine materials like Nickel based super alloys and also complex geometrical shapes of engineering components. Hence non-traditional micro-machining processes have been developed to achieve these goals. Extrusion honing (EH) is one of the non-traditional micro-machining process to debur, radius, polish, and remove recast layer of components in a wide range of applications. Material is removed from the work-piece by flowing abrasive laden medium under pressure through or past the work surface to be finished. Components made up of complex passages having surface/areas inaccessible to traditional methods can be finished to high quality and precision by this process. Hastelloy C22offers resistance to both aqueous corrosion and attack at elevated temperatures and it is a difficult metal to machine using traditional techniques. In this study, extrusion honing of Hastelloy C22 material having passage diameters 7, 8, 9, and 10mm have been performed in an indigenously built hydraulic operated extrusion honing setup using patented polymer as a carrier medium and SiC grit of threegrit sizes (46, 54, and 60) as abrasive at volume concentration of 35%. The internal surface finish results obtained with the use of extrusion honing process are discussed.
