Low Cost Electrochemical Machining (ECM) Processes for Aerospace Components

In the program “Low Cost Electrochemical Machining (ECM) Processes for Aerospace Components�, Faraday Technology Inc., proposes to develop and demonstrate technologies to reduce the capital/operating costs of electrochemical machining of aerospace components and materials such as nickel and titanium alloys. Faraday’s novel approach addresses the current challenges and barriers to wider implementation of electrochemical machining. Specifically, these challenges include high up-front tooling costs and development time, electrolyte and waste management, and machine complexity. Faraday’s innovative approach addresses these challenges while maintaining or enhancing the benefits of ECM such as high material removal rates, excellent final surface finish, adaptability to difficult to machine materials, and fabrication of complex geometries without burrs. The Phase I project will demonstrate the notional requirements on representative aerospace materials, such as nickel (IN625, IN 718) and titanium alloys (6-4, 6-2-4-2) and component geometries. In addition, the use of Multiphysics simulations to predict tool design will be demonstrated. A business case and transition plan will provide the foundation for the Phase II demonstration and validation of the innovative approach on actual representative aerospace components and advance the ECM technology to MRL 5-6.