FARADAYIC Recycling ECM Process and Hardware

This Phase I SBIR program addresses the need for an integrated manufacturing method to recover and recycle metal removed during electrochemical machining. The proposed integrated system combines electrochemical machining, electrowinning, induced codeposition and metal ion concentration to directly recover the machined metal, for engineering materials of interest to the U.S. Army, while maintaining the electrolyte such that it can be immediately returned to the electrochemical machining process. Ideally, a zero-discharge process would be created. In Phase I, we will demonstrate the FARADAYICSM Electrowinning Process and FARADAYIC Electrowinning Cell, targeting the metals of most interest to the Army, copper and steel. Experimental data generated will enable estimates of electrolyte throughput, metal recovery rate, total mass recoverable, cell configuration and validate lack of hazardous material generation. The Phase I Option will extend the technology to other metals, and initiate the design of a pilot-scale facility that will enable relevant volume qualification and quantification of the technology. In Phase II we will build the pilot-scale facility, qualify the technology, and develop more detailed quantification of the reduction in the sludge produced during recycled electrochemical machining. We will investigate other metals and extend the technology to commercial applications, engaging potential strategic alliances.