FARADAYIC Recycling ECM Process and Hardware

This Phase II SBIR addresses the need for an integrated manufacturing method to recover and recycle metal removed during electrochemical machining. FARADAYIC (R)ECM combines electrochemical machining with electrowinning to eliminate sludge and recover machined metal, while maintaining the electrolyte such that it can be immediately returned to the machining process, for a wide variety of metals. This creates a zero-discharge process, consistent with the Army"s"Vision for Net Zero", whereby waste streams are recycled to reclaim valuable materials, eliminate discharge, conserve water, and energy is minimized by elimination of filtration, centrifugation and shipping. Phase I demonstrated the FARADAYICSM Electrowinning Process and Cell targeting metals of interest to the Army, copper, steel and Inconel 718. The machined metal was dissolved in the electrolyte at 3000 ppm, and recovered using electrowinning in solid/metallic form devoid of hydrated oxides. In Phase II we will optimize the FARADAYICSM ECM and FARADAYICSM Electrowinning processes, build bench and pilot-scale facilities to validate the technology in a closed-loop system for steel, copper, nickel and cobalt chrome alloys, develop detailed quantification of the reduction in the sludge produced during recycled electrochemical machining, and design a process flow for implementation at an Army facility.