A pulsed electrochemical machining (pECM) system includes a pECM tool comprising a tool body defining a tool axis, the tool body comprising one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining a working surface at a distal end of the tool axis configured to face a workpiece; an enclosure system configured to hold the workpiece, wherein the enclosure system comprises: a first clamp configured to grip a first end of the workpiece; a second clamp configured to grip a second end of the workpiece; and a backside support configured to support a span of the workpiece between the first end and the second end.

The disclosure describes a method for manufacturing a pulsed electrochemical machining (pECM) tool that includes forming an electrode on a surface of a support substrate. The support substrate includes an electrically non-conductive material. The electrode includes one or more layers of an electrically conductive material and defines a working surface configured to face a workpiece.

The disclosure describes a method for defining an electrode of a pulsed electrochemical machining (pECM) tool that is performed by one or more processors. The method includes receiving workpiece measurement data representative of a machined surface of a machined workpiece. The machined workpiece has been machined by a working surface of an initial electrode. The method includes identifying a set of dimensional differences between the workpiece measurement data and workpiece model data representative of a finished surface of a master workpiece. The method includes updating, based on the set of dimensional differences, initial electrode model data representative of the working surface of the initial electrode and outputting the updated electrode model data.

The invention relates to a method and a device for electrochemically processing a material, which contains a hard phase and a binder phase. The method comprises preparing an aqueous, alkaline, complexing-agent-containing electrolyte and bringing the material to be processed into contact at least in part with the electrolyte and with a current source. In order to electrochemically oxidize the material, a pulsed electrical current is delivered to the material by means of the current source, the pulse sequence of the delivered electrical current being adjusted to the amount of the binder phase in the material to be processed. By means of the method and by means of the device, it is also possible to process materials having a high content of binder phase in such a way that matter can be removed from the material evenly (homogeneously), i.e. both from the hard phase and from the binder phase of the material.

The invention relates to a work station for electrochemically machining a workpiece, having a number of recesses, including a base structure; a module which is fastened to the base structure and is configured to electrochemically machine the workpiece. A workpiece holder is fastened to the base structure. The workpiece holder is movable relative to the base structure along a feed axis which is parallel to the axis of rotation of the module. The module includes an electrode carrier arrangement, which is coupled to the module base body so the electrode carrier arrangement can be rotated together with the module base body about the axis of rotation of the module. The electrode carrier arrangement has a carrier frame and an electrode frame, where at least one electrode is detachably fastened to the electrode frame.

A device for the electrochemical processing of a metal workpiece, including a plurality of electrodes that by way of respective linear drive units are movable in a linear manner relative to the workpiece from an initial position to a terminal position, the electrodes having a reproduction face that is directed toward the workpiece, wherein at least three electrodes are provided, the electrodes being disposed so as to be offset around the circumference of the workpiece and by way of the reproduction faces of the electrodes during the entire readjustment movement from the initial position to the terminal position engaging across one another in portions so as to be in contact, and by way of the reproduction faces of the electrodes delimiting a fluid duct that in a closed manner encircles the circumference of the workpiece.

A method for electropolishing a manufactured metallic article, the method comprising: contacting the metallic article with an electropolishing electrolyte; and electropolishing the metallic article in the electropolishing electrolyte through the application of an applied current regime comprising: at least one electropolishing regime, each electropolishing regime comprising a current density of at least 2 A/cm.sup.2 and a voltage comprising a shaped waveform having a frequency from 2 Hz to 300 kHz, a minimum voltage of at least 0 V and a maximum voltage of between 0.5 to 500 V.

A method of forming a gas turbine engine component including an airfoil and at least one shroud includes the steps of (1) machining a gas path surface of the at least one shroud utilizing a non-electrochemical machining (ECM) process, and (2) then utilizing ECM on at least the airfoil.

A method of operating an electrochemical machining system includes selectively performing an electrochemical machining process by an electrochemical machine of the electrochemical machining system in a macromachining mode or a micromachining mode by controlling a purity level of a machining liquid supplied to the electrochemical machine.

This paper describes an invention involving an electrochemical discharge-enabled micro-grinding process for micro-components of silicon-based materials. The specific machining method is described below. A micro-grinding tool and an auxiliary electrode are respectively connected to the negative and positive electrodes of a pulsed DC power supply. When the current flows through the loop, an electrochemical hydrogen evolution reaction (HER) occurs at the micro-grinding tool in the grinding fluid, which generate multiple hydrogen bubbles. The bubbles coalesce into an insulating gas film and separate the micro-grinding tool from the grinding fluid; when the critical voltage is reached, the gas film is broken down and an electrochemical discharge occurs accompanied by discharge spark; under the action of the discharge spark, the surface material of the workpiece in the discharge-affected region is directly ablated to generate a heat-affected layer (HAL), namely, physical modification.