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

This project will enhance the electrochemical machining process by improving pulse-reverse waveform design to enable ECM on next-generation alloys such as niobium C103 and improve tool design predictions through ECM simulation. Phase I will create a proof-of-concept demonstration of the use of optimal control theory for improving pulse-reverse waveform design on a C103 alloy. Waveform design will be used to maximize material dissolution rates (machining rates), reduce energy costs, and improve the fidelity between workpiece and tool shape.  Electrochemical material-response data collected on the C103 alloy system as a function of pulse-reverse waveforms, along with a Multiphysics finite element model, will be used to create an accurate simulation of the ECM process during pulse-reverse operation. This modeling capability will improve the ability to perform predictions of tool designs needed to achieve given part shapes and reduce the non-recurring engineering expenses of ECM process design. Further work will show the feasibility to generalize the process control methodology for alternative materials of interest for turbine engine components. The end result will be a material-response database and technical know-how that enable enhanced predictions of tool shapes and operational inputs for pulse-reverse ECM processes on next-generation materials.