A Novel Electrochemical Machining Process for Hard Passive Alloys

This Small Business Innovation Research Phase I project will demonstrate a novel process for electrochemical machining nickel superalloys and other hard, passive alloys. Nickel-based superalloys are widely used in various industries, such as aerospace and automative industries. However, nickel superalloys are difficult-to-cut materials. Traditional mechanical methods failed to machine these superalloys. Electrochemical Machining (ECM) is an effective method to machine nickel-based superalloys and other hard, passive alloys due to its high removal rate, no tool wear, and no burrs on the machined surface. However, conventional ECM suffered in poor dimensional accuracy and surface quality caused by cavitation and pitting. Our novel approach will improve the machining accuracy and surface quality for hard, passive alloys by 1) localize current, 2) maintain hydrodynamic uniformity in the interelectrode gap, 3) reduce electrode gap, 4) reduce electrolyte flow rate, and 5) prevent oxide film rehealing problem. The overall objective is to develop a novel electrochemical machining process for hard passive alloys. The specific objective in Phase I is to demonstrate the feasibility to machine nickel-based superalloys with our novel approach to improve dimensional accuracy and surface quality. Anticipated Benefits: Our novel process will be used to machine hard passive alloys, such as nickel-based superalloys. If commercialized, the process is expected to have wide applications in aerospace, automative, and other industries which use hard, passive alloys.