As engineers have increasing capability to design high complexity surfaces with tight tolerance requirements, it is critical that they are aware of all the manufacturing tools available to achieve their designs. Pulsed electrochemical machining (PECM) provides unique capabilities for creating precision features in materials common to the aerospace industry. The non-contact, non-thermal anodic dissolution mechanism of the PECM process can be used to create thin walls and smooth surfaces in a variety of applications including turbine/compressor blades, optical reflectors, and high-temperature heat exchangers.
- The basics of PECM including cathode/tool development, electrolyte selection, pulsed power optimization, and specific material challenges
- Case Study 1: The goal and development of <10 nm Ra roughness while holding form tolerances for an infrared application
- Case Study 2: The applicability and results for creating thin walls (<100um) in super-alloys for turbine blade trailing edges and high-temperature heat exchanger features