Improved Electrochemical Machining of Next-Generation Alloys for Turbine Engine Components through Enhanced Tool Design

Faraday Technology will develop a software application providing electrochemical finite element modeling and computational fluid dynamics capability for electrochemical machining of turbine engine components. The application will perform automated optimization of the cathode tool shape to achieve a target part geometry as specified by the user. Faraday will develop the empirical material-specific data needed to guide the simulation for an Inconel 718 system. Then, Faraday will refine and validate simulation results with electrochemical machining experiments in an iterative manner. Faraday will demonstrate final validation of the efficacy of the software application by using it to reduce the number of experimental iterations required to produce the cathode tool that achieves a given part shape as compared to an industrial process. Use of this application will allow electrochemical machining firms to replace a significant number of upfront experimental iterations during the cathode tool development cycle. This will reduce the non-recurring engineering expenses associated with cathode tool design that are often prohibitive for adoption of electrochemical engineering by small firms as well as decrease reliance on institutional memory and an aging workforce.