SBIR Phase II: A Novel Electrochemical Machining Process for Final Surface Finishing of Hard Passive Alloys

这个小企业创新研究（SBIR）第二阶段项目将开发一种用于硬钝态合金最终表面精加工的电化学加工工艺。 通过传统方法加工硬钝化合金会导致机械或热损伤的表面层。 这种损坏会对零件的性能产生不利影响，必须手动去除，这是一个主要的速度限制步骤，需要总生产时间的25%以上。 新型调制反向电场电化学加工工艺（MREF-ECM）避免了与当前精加工工艺相关的相当大的有形和无形成本，并利用了良性电解质。 第一阶段证明了使用表面受损的INCONEL试样的技术和经济可行性。 第二阶段的工作将使用工业合作伙伴提供的INCONEL和MONEL零件验证MREF-ECM工艺。 将制造工具、夹具和三轴ECM机床，并验证MREF-ECM工艺的技术和经济效益。 在制造环境中，电解液处理和工人暴露问题将被消除。 该工艺适用于航空航天、汽车、工具和模具、医疗器械和热锻行业的零件精加工。

This Small Business Innovation Research (SBIR) Phase II project will develop an electrochemical machining process for final surface finishing of hard passive alloys. Machining of hard passive alloys by traditional methods results in either a mechanically or thermally damaged surface layer. This damage adversely affects the properties of the part and must be removed manually, a major rate limiting step, requiring greater than 25% of total production time . The novel modulated reverse electric field electrochemical machining process (MREF-ECM) avoids the considerable tangible and intangible costs associated with the current finishing process and utilizes benign electrolytes. Phase I demonstrated the technical and economical feasibility using surface damaged INCONEL coupons. Phase II work will validate the MREF-ECM process using INCONEL and MONEL parts provided by an industrial partner. Tooling, fixtures, and a three-axis ECM machine will be fabricated, and the technical and economic benefits of the MREF-ECM process will be validated. In the manufacturing setting, electrolyte disposal and worker exposure issues will be eliminated. The process is applicable to parts finishing in the aerospace, automotive, tool and die, medical implements, and hot forging industries.