SBIR Phase I: A Novel Electrochemical Machining Process for Final Surface Polishing of Hard Passive Alloys

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*** 9760296 Taylor This Small Business Innovation Research (SBIR) Phase I project will explore a novel electrochemical process for final surface finishing of superalloys. Non-traditional machining technologies, such as electrochemical machining (ECM) and electric discharge machining (EDM) , provide near net shape machining of these and other difficult to machine materials or for applications with complex shapes, such as dies, molds, and aircraft parts. However, after ECM or EDM processes, time-consuming robotically controlled precision or manual polishing is required to do the final surface finish. Phase I will demonstrate a modulated reverse electric field process for final surface finishing. A model tool and die geometry, made from a commercially important superalloy, will be utilized to study electrochemical parameters critical to the quality of a finished surface. The electrochemical process is expected to achieve a surface finish less than 20 microns. Final finishing processes account for at least 25% of total processing time and in the case of manual finishing are operator specific. This novel process will find applications aerospace, automotive, die casting, and hot forging industries. ***