NSF Award
9901819
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. <br/> 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.
