A method of forming a component for a gas turbine engine, including: casting a component around a ceramic core, wherein the ceramic core forms a pilot channel (40) in the component, the pilot channel oriented from a base (176) to a tip (20) of the component; sinking an ECM electrode into the pilot channel; and enlarging the pilot channel to form an inner surface of an external wall (120) of the component via electro-chemical machining, wherein a contour (94) of the inner surface is different than a contour of the pilot channel.

A method of forming a component for a gas turbine engine, including: casting a component around a ceramic core, wherein the ceramic core forms a pilot channel (40) in the component, the pilot channel oriented from a base (176) to a tip (20) of the component; sinking an ECM electrode into the pilot channel; and enlarging the pilot channel to form an inner surface of an external wall (120) of the component via electro-chemical machining, wherein a contour (94) of the inner surface is different than a contour of the pilot channel.

A drilling tool for use in machining a conductive work piece that includes a forward electrode tip including an outer radial portion and an inner radial portion. The outer radial portion includes a forward face, and the inner radial portion extends from the forward face of the outer radial portion. The drilling tool further includes a dielectric sheath that extends circumferentially about the outer radial portion, at least one side electrode coupled to the dielectric sheath, and a protective sheath that extends circumferentially about the dielectric sheath. An opening is defined in the protective sheath such that the at least one side electrode is at least partially exposed.

A drilling tool for use in machining a conductive work piece that includes a forward electrode tip including an outer radial portion and an inner radial portion. The outer radial portion includes a forward face, and the inner radial portion extends from the forward face of the outer radial portion. The drilling tool further includes a dielectric sheath that extends circumferentially about the outer radial portion, at least one side electrode coupled to the dielectric sheath, and a protective sheath that extends circumferentially about the dielectric sheath. An opening is defined in the protective sheath such that the at least one side electrode is at least partially exposed.

Provided is an electrode capable of increasing a degree of freedom in machining shape with a simple structure, an electrochemical machining apparatus using the electrode, an electrochemical machining method, and a product machined by the method. An electrode 4 has a core tube 41 formed of a material by which a second hole 101b having a direction or a curvature different from that of a first hole 101a having a predetermined curvature can be formed continuously from the first hole 101a and a coating 42 fixed to an outer periphery of the core tube 41.

Provided is an electrode capable of increasing a degree of freedom in machining shape with a simple structure, an electrochemical machining apparatus using the electrode, an electrochemical machining method, and a product machined by the method. An electrode 4 has a core tube 41 formed of a material by which a second hole 101b having a direction or a curvature different from that of a first hole 101a having a predetermined curvature can be formed continuously from the first hole 101a and a coating 42 fixed to an outer periphery of the core tube 41.

Methods and systems of electrochemically machining a component are provided. The method may include applying two or more potentials to a tool electrode comprising an array of two or more individual electrodes to generate two or more electric fields in between the tool electrode and a workpiece opposite of the tool electrode, wherein each of the two or more electric fields is generated by one of the array of two or more individual electrodes.

A nozzle for an electrochemical machining device. The nozzle defining a body with first and second releasably attachable body portions forming an electrolyte cavity therebetween, when the first and second body portions are attached. The body includes an inlet port upstream of the cavity, and an outlet port for dispensing a jet of electrolyte towards a surface of a workpiece, in use, where a flow path is defined from the inlet port through the cavity to the outlet port.

A nozzle for an electrochemical machining device. The nozzle defining a body with first and second releasably attachable body portions forming an electrolyte cavity therebetween, when the first and second body portions are attached. The body includes an inlet port upstream of the cavity, and an outlet port for dispensing a jet of electrolyte towards a surface of a workpiece, in use, where a flow path is defined from the inlet port through the cavity to the outlet port.

Provided is an electrode capable of increasing a degree of freedom in machining shape with a simple structure, an electrochemical machining apparatus using the electrode, an electrochemical machining method, and a product machined by the method. An electrode 4 has a core tube 41 formed of a material by which a second hole 101b having a direction or a curvature different from that of a first hole 101a having a predetermined curvature can be formed continuously from the first hole 101a and a coating 42 fixed to an outer periphery of the core tube 41.