Electrochemical machining method and system

Abstract

Methods and systems of electrochemical machining are provided. The method can include applying a first electrical potential to a tool electrode of an electrochemical machining system to generate a primary electric field. The electrochemical machining system can include a workpiece opposite the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the at least one bias electrode. The method can also include applying at least one second electrical potential to the at least one bias electrode. The method can also include delivering a charged electrolyte solution through the at least one fluid delivery channel into the electrolyte solution. The application of the at least one second electrical potential and the delivery of the charged electrolyte solution generates at least one secondary electric field adjacent to the primary electric field and quenches at least one location of the primary electric field.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Application No. 17 / 843,254, filed on June 17, 2022, which is incorporated herein in its entirety. Technical Field

[0003] The field of this invention generally relates to electrochemical processing, and more specifically, to methods and systems for performing electrochemical processing. Background Technology

[0004] Electrochemical machining (ECM) is the process of removing conductive materials (such as metallic materials) using electrochemical methods. It is commonly used to machine (including machining or finishing) workpieces made of conductive materials. ECM is often used to provide desired shape control and smooth surface finishes for manufacturing components, including bladed disks of gas turbines, jet engines, and generators, as well as other parts. Attached Figure Description

[0005] This specification sets forth a complete and enabling disclosure for those skilled in the art, including its best mode, with reference to the accompanying drawings, wherein:

[0006] Figure 1 A schematic diagram of an exemplary electrochemical machining system is shown, including a tool electrode and at least one bias electrode.

[0007] Figure 2 A schematic diagram of another exemplary electrochemical processing system according to this disclosure is shown;

[0008] Figure 3 It shows Figure 1 Bottom perspective view of the tool electrode and at least one bias electrode;

[0009] Figure 4 A schematic diagram of a computing system including computing devices is shown, wherein one of the computing devices may perform the same or similar function as the controller of this disclosure; and

[0010] Figure 5 A flowchart of the electrochemical processing method according to the present invention is shown.

[0011] Reference characters are used repeatedly in this specification and drawings to indicate the same or similar features or elements of this disclosure. Detailed Implementation

[0012] Reference will now be made in detail to embodiments of the present disclosure, at least one example of which is illustrated in the accompanying drawings. Each example is provided by way of explanation and not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the disclosure without departing from its scope. For example, features shown or described as part of one embodiment may be used with another embodiment to produce yet another embodiment. Therefore, the disclosure is intended to cover such modifications and variations within the scope of the appended claims and their equivalents.

[0013] The term “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” should not be construed as being more preferred or advantageous than other implementations. Furthermore, unless otherwise specifically indicated, all embodiments described herein should be considered exemplary.

[0014] The terms “connection,” “fixation,” “attachment,” etc., refer to direct connection, fixation, or attachment, as well as indirect connection, fixation, or attachment via at least one intermediate component or feature, unless otherwise specified herein.

[0015] As used herein, the terms “first,” “second,” and “third” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of a single component.

[0016] In the following description and claims, unless the context clearly specifies otherwise, the singular forms “a,” “an,” and “this” include plural references. As used herein, the term “or” is not intended to be exclusive and refers to the presence of at least one referenced component, and includes examples of combinations of referenced components, unless the context clearly specifies otherwise.

[0017] As used herein, the term "quenching" refers to a potential gradient within a specific region of an electric field that is below the standard potential, allowing the workpiece to undergo electrochemical oxidation. As used herein, the term "location" refers to a specific region of the electric field where quenching is occurring. The strength of the electric field cannot be directly measured; however, as described herein, the effect of increasing or decreasing the strength of the electric field at a specific location can be easily observed, allowing one to determine whether the electric field at that location has been quenched.

[0018] As used herein, the term "stray current attack" refers to oxidation of an already electrochemically processed finished part adjacent to the workpiece during ECM of the workpiece. A stray current attack is determined to have occurred when there is evidence that an adjacent finished part has undergone additional material removal and surface pitting due to the workpiece's ECM.

[0019] During the ECM process, a conductive material is oxidized from the workpiece using a potential applied to a tool electrode opposite the workpiece, allowing current to flow at a controlled rate through an electrolyte solution provided between the tool electrode and the workpiece. The workpiece acts as the anode and is separated from the tool electrode, which acts as the cathode, through an electrode gap. The electrolyte solution, typically a salt solution in water, flows through the electrode gap, flushing away the oxidized material from the workpiece. As the tool electrode moves toward the workpiece to maintain the controlled electrode gap, the workpiece is machined into a shape complementary to the tool electrode.

[0020] ECM is particularly suitable for metals and alloys with high hardness, which makes them difficult to machine using conventional methods. For example, ECM can be used to machine nickel-based alloys to manufacture various components, such as bladed disks. When manufacturing bladed disks using ECM, each airfoil is electrochemically machined onto the bladed disk one at a time. Specifically, once a single finished airfoil has been electrochemically machined onto the bladed disk, the bladed disk is rotated to perform ECM on the next airfoil at the location of an adjacent finished airfoil. This process is repeated until the bladed disk has the required number of airfoils.

[0021] However, manufacturing bladed disks with ECM has proven difficult when using more complex metals and alloys, such as titanium-based alloys. Specifically, when using ECM to machine bladed disks with more complex alloys, stray currents tend to travel from the area of ​​the machined airfoil to adjacent, previously finished airfoils on the bladed disk. Stray currents can damage the smooth surface finish of previously finished airfoils, resulting in bladed disks containing airfoils with inconsistent geometry or finish, and impairing component performance. This observation of stray current attacks is not limited to ECMs of compressor bladed disks and can generally be observed in any ECM application where components have closely spaced features, and when using complex metals or alloys.

[0022] Therefore, it is necessary to quench the main electric field generated by the ECM process in a strategic location to counteract stray current attacks from finished components of adjacent workpieces.

[0023] This disclosure provides an ECM process for preventing stray current attacks on finished parts from adjacent workpieces. ECM processes typically involve selective hardening of the primary electric field generated between the tool electrode and the workpiece. The location of the primary electric field can be selectively hardened using a combination of bias anode protection and charged electrolyte delivery. Selective hardening of the primary electric field minimizes stray current attacks and oxidation rates on finished parts from adjacent workpieces that have already undergone ECM. In this regard, the methods and systems described herein utilize a combination of bias anode protection and charged electrolyte flow in electrochemical machining systems to strategically alter the electric field generated during ECM at at least one location within the electrolyte solution to counteract stray current attacks on finished parts from adjacent workpieces. This disclosure provides more efficient management of stray currents and the ability to more precisely control the geometry of the workpiece.

[0024] Now refer to the attached diagram, Figure 1 and 2 Each of the figures illustrates a schematic diagram of an exemplary electrochemical machining system 100 including a tool electrode 120 and at least one bias electrode 140. Specifically, the electrochemical machining system 100 includes a tool electrode 120 configured to generate a primary electric field 200 between the tool electrode 120 and a workpiece 130 opposite to the tool electrode 120. At least one bias electrode 140 is positioned adjacent to the tool electrode 120. Each at least one bias electrode 140 includes at least one fluid delivery channel 144. The at least one bias electrode 140 is configured to generate at least one secondary electric field 210 adjacent to the primary electric field 200.

[0025] In one embodiment, at least one bias electrode 140 is strategically positioned in the region of the electrochemical processing system 100 where stray current attack is expected. For example, in Figure 1 and 2 In an exemplary embodiment, it is contemplated that during ECM operation, stray current attacks may occur on the finished part 150 adjacent to the workpiece 130. Specifically, in the absence of the bias anode protection and charged electrolyte delivery of this disclosure, it is contemplated that the main electric field 200 generated between the tool electrode 120 and the workpiece 130 will be constrained only by the region in which the main electric field 200 will naturally dissipate, thereby allowing stray currents to travel freely from the main electric field 200 to the finished part 150 (if naturally possible). Therefore, in such an exemplary embodiment, Figure 1 and 2In the exemplary embodiment shown, at least one bias electrode 140 is preferably positioned adjacent to the tool electrode 120 and opposite to the workpiece 130, such that a charged electrolyte solution 142 can be delivered through at least one fluid delivery channel 144 via at least one nozzle 141 of the at least one bias electrode 140 into the electrode gap 180 of the electrochemical machining system 100. Therefore, at least one bias electrode 140 suppresses stray current attacks on the finished part 150 adjacent to the workpiece 130.

[0026] The workpiece 130 and at least one bias electrode 140 may comprise any metallic material suitable for an ECM. In one embodiment, the workpiece 130 and at least one bias electrode 140 may each comprise a different metallic material from each other. Alternatively, the workpiece 130 and at least one bias electrode 140 may comprise the same metallic material from each other.

[0027] For example, in one embodiment, the workpiece 130 and at least one bias electrode 140 may comprise a metallic material. In another embodiment, the metallic material may comprise a pure metal or a metal alloy. Pure metals may comprise titanium, niobium, nickel, zirconium, palladium, platinum, aluminum, chromium, manganese, cobalt, molybdenum, hafnium, tungsten, or combinations thereof. Alloys may comprise superalloys, such as titanium-based alloys, niobium-based alloys, nickel-based alloys, zirconium-based alloys, palladium-based alloys, platinum-based alloys, aluminum-based alloys, chromium-based alloys, manganese-based alloys, cobalt-based alloys, molybdenum-based alloys, hafnium-based alloys, tungsten-based alloys, or combinations thereof. However, other metallic materials may be used.

[0028] like Figure 1 and 2 As shown, an exemplary electrochemical machining system 100 includes at least one spacer 160 positioned between at least one bias electrode 140 and a tool electrode 120. The at least one spacer comprises a non-conductive material that electrically isolates the tool electrode 120 from the at least one bias electrode 140. Thus, at least one secondary electric field 210 can be generated adjacent to the primary electric field 200. For example, the at least one spacer 160 may comprise a glass fiber-reinforced non-conductive material, such as a fluoropolymer.

[0029] In one embodiment, at least one spacer 160 may have a thickness of 100 micrometers to 2,500 micrometers, for example, 350 micrometers to 2,000 micrometers, or for example, 500 micrometers to 1,500 micrometers. In one embodiment, at least one spacer 160 may have a thickness of 750 micrometers to 1,000 micrometers.

[0030] The workpiece 130 is separated from the tool electrode 120 through an electrode gap 180, wherein the electrolyte solution 190 is located between the tool electrode 120 and the workpiece 130. The electrode gap 180 can be changed by moving the tool electrode 120, the workpiece 130, or a combination thereof.

[0031] The workpiece 130, tool electrode 120, and at least one bias electrode 140 of the electrochemical machining system 100 can be electrically connected in at least one circuit. In an exemplary embodiment, as shown... Figure 1 As shown, the workpiece 130, tool electrode 120, and at least one bias electrode 140 are electrically connected in a circuit. Furthermore, each of the workpiece 130, tool electrode 120, and at least one bias electrode 140 can be electrically connected in series or in parallel with each other. In an exemplary embodiment, as... Figure 1 As shown, the electrochemical machining system 100 includes at least one bias electrode 140 electrically connected in series with the tool electrode 120 and the workpiece 130. In one embodiment, as... Figure 1 As shown, the electrochemical processing system may include a single power source 170. Alternatively, such as Figure 2 As shown, it illustrates a front schematic of another exemplary electrochemical processing system 100, which can be electrically connected to a first power source 171 and at least one second power source 172.

[0032] Reference Figure 1 and 2 The electrochemical processing system 100 further includes an electrolyte supply source 143 configured to deliver a charged electrolyte solution 142 to at least one fluid delivery channel 144. The electrolyte supply source 143 may contain the electrolyte solution and be in fluid communication with at least one bias electrode 140. The electrolyte supply source 143 can supply the electrolyte solution to at least one bias electrode 140 using any suitable device known in the art. For example, a conventional pump (not shown) can be used to move the electrolyte solution from the electrolyte supply source 143 to at least one bias electrode 140.

[0033] The charged electrolyte solution 142 and the electrolyte solution 190 in the electrode gap 180 may include any suitable electrolyte, such as a base, acid, or ionic liquid. In some embodiments, the electrolyte solution 190 includes an ionic salt, a dicarboxylic acid, an organic acid, a deep eutectic, a molten salt, or a combination thereof. The charged electrolyte solution 142, electrolyte solution 190, or both may be an aqueous electrolyte, such as an aqueous salt electrolyte comprising water and at least one salt. In one embodiment, the charged electrolyte solution 142, electrolyte solution 190, or both may include an aqueous salt electrolyte comprising sodium nitrate, sodium chloride, sodium bromide, sodium hydroxide, perchloric acid, phosphoric acid, or a combination thereof. In some embodiments, the charged electrolyte solution 142, electrolyte solution 190, or both may constitute 10% to 30% sodium nitrate (parts by weight). For example, an electrolyte solution constituting 20% ​​sodium nitrate (parts by weight) can be used for electrochemically processing nickel-based alloys, such as Inconel 718 (a nickel-iron alloy). Additionally, the charged electrolyte solution 142, electrolyte solution 190, or both are typically pH-adjusted according to the material being electrochemically processed. For example, the electrolyte can be adjusted to have a pH of 5-10. It should be understood that other aqueous electrolytes can be used with the techniques disclosed herein.

[0034] like Figure 1-2 As shown, the electrochemical machining system 100 may further include a controller 112, a power supply 170, and an actuator 113. The controller 112 may be operatively connected to the power supply 170 for adjusting the voltages of a first potential and at least one second potential as needed. The controller 112 may be further operatively connected to the actuator 113 for adjusting the position of the tool electrode 120 and / or the workpiece 130 during the ECM process. As used herein, the phrase “operatively connected” should be understood to mean that the components can be directly connected (e.g., mechanically or electrically) or connected via other components.

[0035] Although shown as separate units in the figures, the controller 112 and the power supply 170 may be a combined unit. Furthermore, in some embodiments, the controller 112 may be coupled with… Figure 4 The computing system 400 is constructed and operates in the same or similar manner as the computing device 402.

[0036] Now for reference Figure 3 It shows Figure 1 and 2 A bottom perspective view of the tool electrode 120 and at least one bias electrode 140. The at least one bias electrode 140 can be positioned relative to the tool electrode 120 in various ways. For example, as... Figure 3As shown, the bottom surface of the tool electrode 120 can have a generally circular shape, wherein each bias electrode 140 is positioned radially equidistant from each other around the tool electrode 120. However, other configurations may be employed as needed, as the configuration of the tool electrode 120 and at least one bias electrode 140 depends at least on the shape of the workpiece 130 and the location where stray current attacks are intended to be minimized.

[0037] Figure 4 An exemplary computing system 400 is provided according to exemplary embodiments of this subject matter. The controller 112 described herein may include various components of at least one computing device 402 of the computing system 400 described below and perform its various functions.

[0038] like Figure 4 As shown, the computing system 400 may include at least one computing device 402. The computing device 402 may include at least one processor 404 and at least one memory device 406. The at least one processor 404 may include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, and / or other suitable processing device. The at least one memory device 406 may include at least one computer-readable medium, including but not limited to non-transitory computer-readable media, RAM, ROM, hard disk drive, flash drive, and / or other memory devices.

[0039] At least one memory device 406 may store information accessible by at least one processor 404, including computer-readable instructions 408 executable by at least one processor 404. Instructions 408 may be any set of instructions that, when executed by at least one processor 404, cause at least one processor 404 to perform any operation as described herein. For example, the methods provided herein may be implemented wholly or partially by computing system 400. Instructions 408 may be software written in any suitable programming language or may be implemented in hardware. Additionally and / or alternatively, instructions 408 may be executed in logically and / or practically separate threads on processor 404. Memory device 406 may further store data 410 accessible by processor 404. For example, data 410 may include models, databases, etc.

[0040] The computing device 402 may also include a network interface 412 for communicating, for example, with other components of the electrochemical processing system 100 (e.g., via a network). The network interface 412 may include any suitable components for communicating with at least one network interface, including, for example, a transmitter, receiver, port, antenna, and / or other suitable components.

[0041] In another embodiment, generally provided as follows Figure 5The flowchart illustrates a method 700 for electrochemically machining a workpiece. The method includes 710 applying a first potential to a tool electrode of an electrochemical machining system to generate a primary electric field. The electrochemical machining system includes a workpiece opposite the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the bias electrode. The primary electric field is generated within an electrolyte solution between the tool electrode and the workpiece. The method further includes 720 applying at least one second potential to the at least one bias electrode. The method further includes 730 delivering a charged electrolyte solution into the electrolyte solution through the at least one fluid delivery channel. Applying at least one second potential and delivering the charged electrolyte solution generates at least one secondary electric field adjacent to the primary electric field, and quenching at least one location of the primary electric field. The combination of bias anode protection and charged electrolyte delivery creates robust operation for electrochemical machining of complex geometries while combating stray current attacks from adjacent finished surfaces, using materials that are difficult to machine.

[0042] In some embodiments, the delivery of a charged electrolyte solution through at least one fluid delivery channel within at least one bias electrode, combined with the application of at least one second potential to at least one bias electrode, provides the ability to locally alter the master electric field and influence the rate of localized material oxidation, including the workpiece and adjacent finished parts. In particular embodiments, the strategic arrangement of at least one bias electrode, combined with the delivery of charged electrolyte through at least one fluid channel, allows the master electric field to be quenched at strategic locations and is generally constrained by the actual location of the electrochemical machining. Therefore, a method for more precise control of the master electric field is generally provided to counteract stray current attacks on adjacent finished parts.

[0043] During operation, the workpiece 130 can be used as an anode and the tool electrode 120 can be used as a cathode, generating a primary electric field 200 between the workpiece 130 and the tool electrode 120. In addition, at least one bias electrode 140 can be used as an anode and the tool electrode 120 can be used as a cathode, generating at least one secondary electric field 210 adjacent to the primary electric field 200 between each at least one bias electrode 140 and the tool electrode 120.

[0044] As discussed, a single power source 170 may be electrically connected to the electrochemical processing system 100. In one embodiment, the method may include using the single power source 170 to apply a first potential and at least one second potential to the electrochemical processing system 100.

[0045] In another embodiment, the method may include applying a first potential to the electrochemical processing system 100 using a first power source 171, and applying at least one second potential to the electrochemical processing system 100 using at least one second power source 172. Applying the first potential to the electrochemical processing system 100 generates a primary electric field 200, while applying at least one second potential to the electrochemical processing system 100 generates at least one secondary electric field 210 adjacent to the primary electric field 200.

[0046] Each of the at least one second potential can be a different voltage from each other. That is, at least one second potential can include two or more second potentials with different voltages from each other. This provides precise control over the oxidation of workpiece 130 at selective locations on workpiece 130, because each of the at least one secondary electric field 210 can be generated to remove material from workpiece 130 at a different oxidation rate. Alternatively, at least two or more of the second potentials can be the same voltage.

[0047] In one embodiment, the first potential applied to the electrochemical processing system 100 may be a first DC potential of 5V to 50V, for example, 5V to 35V. In one embodiment, at least one second potential applied to the electrochemical processing system 100 may be at least one second DC potential of 1V to 50V, for example, 1V to 35V, for example, 1V to 10V.

[0048] In one embodiment, the method may include applying a first potential to the electrochemical machining system 100, wherein the first potential is a first pulsed potential. Similarly, the method may include applying at least one second potential to the electrochemical machining system 100, wherein the at least one second potential applied to the electrochemical machining system 100 is at least one second pulsed potential. Specifically, the power supply 170 may be configured to provide a first pulsed potential, at least one second pulsed potential, or a combination thereof in the form of a pulsed potential (more specifically, a bipolar pulsed potential). In one embodiment, a first pulsed potential is applied to a tool electrode 120 to electrochemically remove a predetermined amount of material from a workpiece 130, while at least one second pulsed potential is applied to at least one bias electrode 140 to generate at least one secondary electric field 210.

[0049] As used herein, the term "average potential" is the average of the off-time potential and the on-time potential of each pulse potential. In some embodiments, the average potential of the first pulse potential may be in the range of 1 volt to 5 volts. Additionally, the average potential of at least one second pulse potential may be in the range of 1-5 volts.

[0050] In one embodiment, power supply 170 may include a bipolar power supply and may be configured to perform pulse train control. In another embodiment, controller 112 may be configured to adjust the pulse duration, frequency, and voltage of a first pulse potential applied to tool electrode 120 and workpiece 130 and a second pulse potential applied to tool electrode 120 and at least one bias electrode 140 as needed.

[0051] For example, the pulse duration of the first pulse potential, at least one second pulse potential, or a combination thereof can be from 10 nanoseconds to 1000 microseconds, such as from 10 nanoseconds to 50 microseconds. Additionally, in one embodiment, the voltage applied to the first pulse potential, at least one second pulse potential, or a combination thereof can be from 10 volts to 50 volts, such as from 15 volts to 25 volts.

[0052] Furthermore, in some embodiments, the method includes controlling the distance between the tool electrode 120 and the workpiece 130 (i.e., the length of the electrode gap 180) to be greater than 0.05 mm, for example, greater than 0.1 mm. In some embodiments, the method includes controlling the distance between the tool electrode 120 and the workpiece 130 to be from 0.1 mm to 2 mm, for example, from 0.5 mm to 1.5 mm.

[0053] In one embodiment, the method includes delivering a charged electrolyte solution into an electrolyte solution 730 via at least one fluid delivery channel. Specifically, the charged electrolyte solution is delivered from an electrolyte supply source into an electrode gap via at least one fluid delivery channel within at least one bias electrode.

[0054] In an exemplary embodiment, as the electrolyte solution is delivered from an electrolyte supply source to at least one bias electrode, a power source may be electrically connected to the at least one bias electrode. By applying at least one second potential to the at least one bias electrode, the electrolyte solution transported from the electrolyte supply source can be charged and converted into a charged electrolyte solution. At this point, the charged electrolyte solution can be delivered through at least one fluid delivery channel and discharged from the at least one bias electrode onto a specific area of ​​the workpiece through at least one nozzle, thereby altering the main electric field and counteracting stray current attacks from adjacent finished parts of the workpiece.

[0055] In an exemplary embodiment, the charged electrolyte solution exits at least one nozzle 141 at a rate of 1 L / min to 50 L / min, for example 1 L / min to 25 L / min, for example 1 L / min to 10 L / min, for example 1 L / min to 5 L / min.

[0056] In some cases, in conjunction with the delivery of charged electrolyte, the electrolyte solution 190 can be continuously forced through the electrode gap 180 at a flow rate of 0.5 L / s to 20 L / s (e.g., 3.75 L / s to 10 L / s) to flush the workpiece 130 and the tool electrode 120. Alternatively, the electrolyte solution 190 can be continuously forced through the electrode gap 180 at a pressure of 350,000 Pa to 3,500,000 Pa.

[0057] In certain embodiments, a combination of bias anode protection and charged electrolyte delivery has been shown to exhibit a reduced amount of "stray current attack" on the surface of the finished part adjacent to the electrochemically machined workpiece. Evidence of this reduction in "stray current attack" on the adjacent finished part 150 is shown by the reduced amount of additional material removal and surface pitting experienced by the finished part 150 during the electrochemical machining of the workpiece 130, compared to electrochemically machining the workpiece 130 under the same conditions without bias anode protection and charged electrolyte delivery.

[0058] In one embodiment, delivering a charged electrolyte solution substantially reduces the oxidation rate of the finished part 150 adjacent to the workpiece 130. Similarly, the reduction in the oxidation rate of the finished part 150 is demonstrated by a reduction in the amount of additional material removal and surface pitting experienced by the finished part 150 during the electrochemical machining of the workpiece 130 compared to electrochemical machining of the workpiece 130 under the same conditions without bias anode protection and delivery of charged electrolyte.

[0059] Therefore, as described herein, this subject matter provides improved electrochemical machining methods and systems. For example, the current state of the prior art requires manual physical masking of finished parts adjacent to workpieces to protect their surfaces from stray current attacks. In contrast, the combination of bias anode protection and charged electrolyte delivery as described in this disclosure allows for automated closed-loop control of the main electric field of the electrochemical machine, as well as serial machining of workpieces adjacent to finished parts by enhancing the degree of protection against stray current attacks, all without the need for manual masking. Specifically, as described herein, the combination of bias anode protection and charged electrolyte delivery provides selective hardening at specific locations in the main electric field, ensuring the quality of adjacent finished parts, even on parts with closely spaced complex features, such as bladed disks. Furthermore, the systems and methods described herein can be retrofits of existing machines.

[0060] The technologies discussed herein refer to computer-based systems and the actions taken by and from computer-based systems, as well as the information sent to and from computer-based systems. Those skilled in the art will recognize that the inherent flexibility of computer-based systems allows for a wide variety of possible configurations, combinations, and divisions of tasks and functions between and within components. For example, the processes discussed herein can be implemented using a single computing device or multiple computing devices working in combination. Databases, memory, instructions, and applications can be implemented on a single system or distributed across multiple systems. Distributed components can operate sequentially or in parallel.

[0061] Further aspects of this disclosure are provided by the subject matter of the following clauses:

[0062] A method for electrochemically machining a workpiece, the method comprising: applying a first potential to a tool electrode of an electrochemical machining system to generate a main electric field, wherein the electrochemical machining system includes a workpiece opposite to the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the at least one bias electrode; wherein the main electric field is generated in an electrolyte solution between the tool electrode and the workpiece; applying at least one second potential to the at least one bias electrode; and delivering a charged electrolyte solution into the electrolyte solution through the at least one fluid delivery channel, wherein applying at least one second potential and delivering the charged electrolyte solution generates at least one secondary electric field adjacent to the main electric field and quenching at least one location of the main electric field.

[0063] According to any of the methods described herein, at least one spacer is positioned between at least one bias electrode and a tool electrode.

[0064] According to any one of the methods described herein, at least one spacer has a thickness of 100 micrometers to 2500 micrometers.

[0065] According to any of the methods described herein, at least one bias electrode is electrically connected in series with the tool electrode and the workpiece.

[0066] According to any of the methods described herein, the first potential is a DC potential of 5 to 50 volts.

[0067] According to any of the methods described herein, at least one second potential is a direct current potential of 1 volt to 10 volts.

[0068] According to any one of the methods described herein, the first potential is a first pulse potential, and at least one second potential is at least one second pulse potential.

[0069] According to any of the methods described herein, the first pulse potential has an average potential of 1 volt to 5 volts.

[0070] According to any of the methods described herein, at least one second pulse potential has an average potential of 1 volt to 5 volts.

[0071] According to any one of the methods described herein, the charged electrolyte solution is charged in at least one fluid transport channel by at least one second potential.

[0072] According to any one of the methods described herein, the charged electrolyte solution exits at least one nozzle of at least one electrode at a rate of 1 L / min to 50 L / min.

[0073] According to any one of the methods described herein, the workpiece and at least one bias electrode comprise a metallic material, the metallic material comprising a metallic alloy, and the metallic alloy comprising titanium-based alloys, niobium-based alloys, nickel-based alloys, zirconium-based alloys, palladium-based alloys, platinum-based alloys, aluminum-based alloys, chromium-based alloys, manganese-based alloys, cobalt-based alloys, molybdenum-based alloys, hafnium-based alloys, tungsten-based alloys, or combinations thereof.

[0074] According to any of the methods described herein, the delivery of a charged electrolyte solution substantially reduces the oxidation rate of the finished component adjacent to the workpiece.

[0075] According to any of the methods described in this article, the finished component is an airfoil.

[0076] According to any of the methods described herein, at least one second potential comprises two or more second potentials with different voltages from each other.

[0077] An electrochemical machining system includes: a tool electrode configured to generate a primary electric field between the tool electrode and a workpiece opposite to the tool electrode; and at least one bias electrode located adjacent to the tool electrode, wherein the at least one bias electrode includes at least one fluid delivery channel and is configured to generate at least one secondary electric field adjacent to the primary electric field.

[0078] According to any of the items described herein, in an electrochemical machining system, at least one bias electrode is electrically connected in series with a tool electrode and a workpiece.

[0079] The electrochemical processing system according to any one of the items herein further includes a power source electrically connected to at least one bias electrode and a tool electrode.

[0080] The electrochemical processing system according to any one of the items herein further includes an electrolyte supply source configured to deliver a charged electrolyte solution to at least one fluid delivery channel.

[0081] According to any of the electrochemical machining systems described herein, at least one spacer is positioned between at least one bias electrode and a tool electrode.

[0082] This written description uses exemplary embodiments to disclose this disclosure, including the best mode, and also enables those skilled in the art to practice this disclosure, including making and using any device or system and performing any combined methods. The patentable scope of the invention is defined by the claims, but may include other examples that would occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they comprise structural elements that are not different from the literal language of the claims, or if they comprise equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A method for electrochemically machining a workpiece, characterized in that, The method includes: A first potential is applied to a tool electrode of an electrochemical machining system to generate a main electric field, wherein the electrochemical machining system includes a workpiece opposite the tool electrode, at least one bias electrode, and at least one fluid delivery channel within the at least one bias electrode; wherein the main electric field is generated within an electrolyte solution between the tool electrode and the workpiece; At least one second potential is applied to the at least one bias electrode; and A charged electrolyte solution is delivered to the electrolyte solution through the at least one fluid delivery channel, wherein at least one second potential is applied and the delivery of the charged electrolyte solution generates at least one secondary electric field adjacent to the main electric field and quenches at least one location of the main electric field.

2. The method according to claim 1, characterized in that, in, At least one spacer is positioned between the at least one bias electrode and the tool electrode.

3. The method according to claim 2, characterized in that, in, The at least one spacer has a thickness of 100 micrometers to 2500 micrometers.

4. The method according to claim 1, characterized in that, in, The at least one bias electrode is electrically connected in series with the tool electrode and the workpiece.

5. The method according to claim 1, characterized in that, in, The first potential is a direct current potential of 5 volts to 50 volts.

6. The method according to claim 1, characterized in that, in, The at least one second potential is a direct current potential of 1 volt to 10 volts.

7. The method according to claim 1, characterized in that, in, The at least one second potential includes two or more second potentials that are different voltages from each other.

8. The method according to claim 1, characterized in that, in, The first potential is a first pulse potential, and the at least one second potential is at least one second pulse potential.

9. The method according to claim 8, characterized in that, in, The first pulse potential has an average potential of 1 volt to 5 volts.

10. The method according to claim 8, characterized in that, in, The at least one second pulse potential has an average potential of 1 volt to 5 volts.

11. The method according to claim 1, characterized in that, in, The charged electrolyte solution is charged in the at least one fluid transport channel by the at least one second potential.

12. The method according to claim 1, characterized in that, in, The charged electrolyte solution exits from at least one nozzle of the at least one bias electrode at a rate of 1 L / min to 50 L / min.

13. The method according to claim 1, characterized in that, in, The workpiece and the at least one bias electrode comprise a metallic material, which comprises a metal alloy, including titanium-based alloys, niobium-based alloys, nickel-based alloys, zirconium-based alloys, palladium-based alloys, platinum-based alloys, aluminum-based alloys, chromium-based alloys, manganese-based alloys, cobalt-based alloys, molybdenum-based alloys, hafnium-based alloys, tungsten-based alloys, or combinations thereof.

14. The method according to claim 1, characterized in that, in, The delivery of the charged electrolyte solution substantially reduces the oxidation rate of the finished components adjacent to the workpiece.

15. The method according to claim 14, characterized in that, in, The finished component is an airfoil.

16. An electrochemical machining system, characterized in that, include: A tool electrode configured to generate a main electric field between the tool electrode and a workpiece opposite to the tool electrode; and At least one bias electrode is positioned adjacent to the tool electrode, wherein the at least one bias electrode includes at least one fluid delivery channel, the at least one bias electrode is configured to generate at least one secondary electric field adjacent to the primary electric field, and to quench the potential at at least one location of the primary electric field.

17. The electrochemical processing system according to claim 16, characterized in that, Further includes: At least one spacer is positioned between the at least one bias electrode and the tool electrode.

18. The electrochemical processing system according to claim 16, characterized in that, in, The at least one bias electrode is electrically connected in series with the tool electrode and the workpiece.

19. The electrochemical processing system according to claim 16, characterized in that, It further includes a power supply electrically connected to the at least one bias electrode and the tool electrode.

20. The electrochemical processing system according to claim 16, characterized in that, Further includes: An electrolyte supply source configured to deliver a charged electrolyte solution to the at least one fluid delivery channel.

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