Electrolytic machining method and system

Abstract

To provide methods and systems of electrochemically machining a component.SOLUTION: 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 between the tool electrode and a workpiece opposite to 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.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The field of the present disclosure generally relates to electrochemical machining, and more particularly, to methods and systems for performing electrochemical machining.

Background Art

[0002] Electrochemical machining (ECM) is a process of removing conductive materials such as metallic materials by an electrochemical process. ECM is typically used for machining (machining / finishing) workpieces made of conductive materials. ECM is particularly useful for high-hardness metals and alloys that are difficult to machine by conventional methods. For example, nickel-based alloys can be machined using ECM to manufacture various components.

[0003] During the ECM process, an applied potential is used to oxidize the conductive material from the workpiece so that current flows at a controlled rate. The workpiece functions as an anode and is separated from the tool electrode, which functions as a cathode, by a gap. An electrolyte (usually brine in water) flows through the gap and washes away the oxide material from the workpiece. When the tool electrode moves towards the workpiece to maintain a controlled gap, the workpiece is machined into the complementary shape of the tool electrode.

Summary of the Invention

Means for Solving the Problems

[0004] A complete and realizable disclosure, including its best mode, directed to those skilled in the art, is described herein with reference to the accompanying drawings.

Brief Description of the Drawings

[0005]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5A

Figure 5B

Figure 5C

Figure 5D

Figure 6

[0006] The repeated use of reference characters in this specification and drawings is intended to represent the same or similar features or elements of the present disclosure.

[0007] Next, preferred embodiments are referred to in detail, and one or more examples thereof are shown in the drawings. Each example is provided as an illustration of the invention and is not intended to limit the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to obtain yet another embodiment. Accordingly, the present disclosure is intended to cover such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0008] As used herein, the term "exemplary" means "an example, instance, or serves as an example." Implementations described as "exemplary" herein need not be construed as preferred or advantageous over other implementations. Further, unless otherwise specified, all embodiments described herein should be considered exemplary.

[0009] Terms such as "coupled," "fixed," "attached," etc., unless otherwise specified herein, refer to both direct coupling, fixing, or attachment and indirect coupling, fixing, or attachment via at least one intermediate component or mechanism.

[0010] As used herein, the terms "first," "second," and "third" may be used in the same sense to distinguish one component from another and do not necessarily imply the position or importance of individual components.

[0011] In the following specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. As used herein, the term "or" is not meant to be exclusive and refers to the presence of at least one of the referenced components, including cases where combinations of the referenced components are present, unless the context clearly dictates otherwise.

[0012] As used herein, "minimum dimension" refers to the degree of precision that an electrochemical machine can produce on a workpiece. In current state-of-the-art technology, a tool electrode positioned close to a workpiece can generally reproduce a surface with a minimum dimension of 2.54 μm or greater on the workpiece.

[0013] During the ECM process, the applied potential is used to oxidize the conductive material from the workpiece, causing current to flow at a controlled rate. The workpiece functions as the anode and is separated from the tool electrode, which functions as the cathode, by a gap. An electrolyte (usually saline in water) flows through the gap, flushing away the oxide material from the workpiece. As the tool electrode moves towards the workpiece to maintain a controlled gap, the workpiece is machined into the complementary shape of the tool electrode.

[0014] ECM generally provides desirable shape control and a smooth surface finish for the manufacture of components, including bladed disks and other components, such as in gas turbines, jet engines, and power generation. ECM, which uses an oxidation reaction to remove material, is typically achieved using a solid metal cathode that is approximately the inverse image of the desired final shape. Although ECM is used in many high-volume applications, there are limitations, such as a lack of the general ability to form components with accurate geometric fidelity. For example, a tool electrode operating on a workpiece positioned in proximity to the tool electrode can typically reproduce surfaces with a minimum dimension of 2.54 micrometers (μm). However, because additive manufacturing for producing components with densely packed features or complex shapes is widely adopted, it is generally desirable to improve ECM applications to enable the manufacture of components with minimum dimensions and repeating surface patterns with tolerances that exceed modern ECM capabilities.

[0015] The present disclosure describes an electrode configuration that incorporates an array of individual electrodes rather than a monolithic tool electrode. Further, the present disclosure describes an electrode configuration that incorporates a structure that enables flushing of the electrolyte to regulate mass transport of ionic species and utilizes a specific applied potential for each individual electrode.

[0016] Specifically, the present disclosure provides an ECM process for electrochemically machining a workpiece in an electrochemical machining system that uses a tool electrode including an array of two or more individual electrodes, and can provide high-fidelity and / or sub-micron features on the workpiece. The ECM process generally includes the use of a tool electrode including an array of two or more individual electrodes, in which two or more potentials are individually applied to each of the two or more individual electrodes, resulting in the generation of two or more electric fields. In this regard, a unique potential can be applied to each of the two or more individual electrodes, and through the tool electrode, the oxidation rate of the workpiece can be individually controlled at strategic locations on the workpiece, enabling the workpiece being machined to have high-fidelity or sub-micron features (i.e., minimum dimensions of 2.54 μm or less, such as, as non-limiting examples, from 1 μm to 2.50 μm, or as further non-limiting examples, from 1.25 μm to 2.25 μm).

[0017] Referring now to the drawings, FIG. 1 shows a front schematic view of an exemplary electrochemical machining (ECM) system 100 including a tool electrode 120 that includes an array of two or more individual electrodes 140 that are not operating. FIG. 2 shows a front schematic view of an exemplary ECM system 100 including a tool electrode 120 that includes an array of two or more individual electrodes 140 that are operating. The workpiece 130 is separated from the tool electrode 120 by an electrode gap 180, and an electrolyte solution 190 is interposed between the tool electrode 120 and the workpiece 130. The array is shown as including a first electrode 143 and a second electrode 144, but the array of two or more individual electrodes 140 is not limited to two electrodes. At least one spacer 160 is disposed between the first electrode 143 and the second electrode 144 of the array of two or more individual electrodes 140. The at least one spacer 160 includes at least one electrolyte flushing channel 141 and at least one electrolyte flushing port 146. The exemplary ECM system 100 includes an electrolyte solution and further includes an electrolyte source 145 in fluid communication with the at least one electrolyte flushing channel 141 of the at least one spacer 160. The ECM system 100 further includes a controller 112, a power supply 170, and an actuator 113.

[0018] Generally, at least one of the workpiece 130 and the array of two or more individual electrodes 140 includes a metal material suitable for ECM. Further, in one embodiment, the workpiece 130 and the array of two or more individual electrodes can each include a metal material unique to each other. Alternatively, the workpiece 130 and the two or more individual electrodes can each include the same metal material. Further, in one embodiment, the first electrode 143 and the second electrode 144 can each include a metal material unique to each other. Alternatively, the first electrode 143 and the second electrode 144 can each include the same metal material.

[0019] Furthermore, in one embodiment, the metal material of the present disclosure may include a pure metal or a metal alloy. The pure metal may include titanium, niobium, nickel, zirconium, palladium, platinum, or aluminum. In one embodiment, the alloy of the present disclosure may include a titanium-based alloy, a niobium-based alloy, a nickel-based alloy, a zirconium-based alloy, a palladium-based alloy, a platinum-based alloy, an aluminum-based alloy, or a combination thereof. However, other metal materials or alloys including titanium aluminide alloys can also be used.

[0020] Two or more individual electrodes of the workpiece 130 and the electrochemical machining system 100 may be electrically connected in at least one electrical circuit. In an exemplary embodiment, as shown in FIGS. 1 and 2, the workpiece 130 and two or more individual electrodes are electrically connected within one circuit. However, in another embodiment, the workpiece 130 and two or more individual electrodes may be electrically connected in two or more circuits. Further, in one embodiment shown in FIGS. 1 and 2, the first electrode 143 and the second electrode 144 may be electrically connected in parallel with the workpiece 130.

[0021] The electrolyte solution 190 interposed between the tool electrode 120 and the workpiece 130 can include any suitable electrolyte such as a base, an acid, or an ionic liquid. In some embodiments, the electrolyte solution 190 includes an ionic salt, a dibasic acid, an organic acid, a deep eutectic, a molten salt, or a combination thereof. The electrolyte solution may be an aqueous electrolyte such as an aqueous salt electrolyte containing water and at least one salt. In one embodiment, the electrolyte solution 190 includes an aqueous salt electrolyte containing sodium nitrate, sodium chloride, sodium bromide, or a combination thereof. In some embodiments, the electrolyte solution 190 can constitute an aqueous salt solution from 10 weight percent to 30 weight percent. For example, the electrolyte solution 190 containing 20 weight percent sodium nitrate can be used for electrolytic machining of nickel-based alloys such as Inconel 718. Further, the electrolyte is generally pH-adjusted according to the material to be electrolytically machined. For example, the electrolyte can be pH-adjusted to have a pH from 5 to 10. However, it will be understood that other aqueous electrolytes can also be used in the techniques of the present disclosure.

[0022] As shown in FIGS. 1 and 2, an exemplary electrolytic machining system 100 includes at least one spacer 160. The at least one spacer 160 can be disposed between the first electrode 143 and the second electrode 144. As shown in FIG. 2, the at least one spacer 160 includes a non-conductive material, and the non-conductive material electrically insulates the first electrode 143 and the second electrode 144 from each other so that the generation of two or more electric fields 200 is achieved between the tool electrode 120 and the workpiece 130 during the operation of the electrolytic machining system 100. For example, the at least one spacer 160 may include a glass fiber-reinforced non-conductive material such as a fluoropolymer.

[0023] In one embodiment, at least one spacer 160 may have a thickness of from 100 micrometers to 2500 micrometers, such as from 350 micrometers to 2000 micrometers, such as from 500 micrometers to 1500 micrometers. In one embodiment, at least one spacer 160 may have a thickness of from 750 micrometers to 2000 micrometers.

[0024] In one embodiment, the electrochemical machining system 100 further includes an electrolyte source 145 configured to deliver a charged or uncharged electrolyte solution 142 to at least one electrolyte flushing port 146. The electrolyte source 145 may contain an electrolyte solution and be in fluid communication with at least one electrolyte flushing port 146 of at least one spacer 160. The electrolyte source 145 can supply the electrolyte solution to at least one spacer 160 using any suitable means known in the art. For example, a conventional pump (not shown) can be used to move the electrolyte solution from the electrolyte source 145 to at least one spacer 160.

[0025] FIG. 3 shows a bottom perspective view of the tool electrode 120 of FIGS. 1 and 2. As shown, at least one spacer 160 is preferably positioned on the opposite side of the workpiece 130 such that a charged or uncharged electrolyte solution 142 (FIG. 2) can be delivered through at least one electrolyte flushing port 146 into the electrode gap 180 (FIGS. 1 and 2) of the electrochemical machining system 100 (FIGS. 1 and 2). In this regard, particularly in conventional flow box applications, flushing of any material electrochemically machined from the workpiece 130 (FIGS. 1 and 2) can be enhanced.

[0026] At least one electrolyte flushing port 146 is, as shown in FIGS. 1-3, a hollow cavity of at least one spacer 160 and is generally cylindrical in shape. Further, as shown in FIG. 3, at least one electrolyte flushing port 146 is disposed generally centrally of at least one spacer 160. However, the three-dimensional geometry of the electrolyte flushing port 146 may be of other shapes and may be disposed at other locations of at least one spacer 160, so long as the charged or uncharged electrolyte solution 142 can sufficiently "wash away" the material machined electrolytically from the workpiece 130.

[0027] As used herein, the expression "operatively connected" should be understood to mean that each component can be directly connected (e.g., mechanically or electrically) or can be connected via other components. In one embodiment, 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 to adjust the voltage of two or more potentials as desired. The controller 112 may further be operatively connected to the actuator 113 to adjust the position of the tool electrode 120 and / or the workpiece 130 during the ECM process. The controller 112 and the power supply 170 are shown as separate units in FIGS. 1 and 2, but may be combined units. Further, the controller 112 may include a single controller 112 configured to adjust two or more potentials applied to the electrochemical machining system 100, as shown in FIGS. 1-2. Alternatively, the controller 112 may include two or more controllers 112, each of the two or more controllers 112 being configured to adjust one of two or more potentials applied to the electrochemical machining system 100. Further, in some embodiments, the controller 112 may be configured and may function in the same or similar manner as one of the computing devices 402 of the computing system 400 of FIG. 4.

[0028] FIG. 4 provides an exemplary computing system 400 according to an exemplary embodiment of the present subject matter. The controller 112 described herein includes various components and can execute various functions of at least one computing device 402 of the computing system 400 described below.

[0029] As shown in FIG. 4, 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, a microcontroller 112, an integrated circuit, a logic device, and / or other suitable processing devices. The at least one memory device 406 may include at least one computer-readable medium including, but not limited to, a non-transitory computer-readable medium, RAM, ROM, a hard drive, a flash drive, and / or other memory devices.

[0030] At least one memory device 406 can store information accessible by at least one processor 404, including computer-readable instructions 408 executable by at least one processor 404. The computer-readable instructions 408 can be any set of instructions that, when executed by at least one processor 404, cause the at least one processor 404 to perform operations such as any of the operations described herein. For example, the methods provided herein can be implemented, in whole or in part, by computing system 400. The computer-readable instructions 408 can be software written in any suitable programming language or can be implemented in hardware. Further, and / or alternatively, the computer-readable instructions 408 can be executed in logical and / or virtual separate threads on processor 404. The memory device 406 can further store data 410 accessible by processor 404. For example, the data 410 can include models, databases, and the like.

[0031] Computing device 402 can also include, for example, a network interface 412 used to communicate (e.g., via a network) with other components of the electrochemical machining system 100. The network interface 412 can include any suitable components for interfacing with at least one network, including, for example, a transmitter, a receiver, a port, an antenna, and / or other suitable components.

[0032] In one embodiment, the electrochemical machining system 100 is utilized in a conventional flow box application, as generally shown in FIGS. 1-2. Alternatively, the disclosed electrochemical machining system 100 can be operated open for machining operations without using an electrolyte storage box, as generally shown in FIGS. 5A-5D. This type of configuration can also control the oxidation of workpiece 130 at strategic locations on surface 131 of workpiece 130, in accordance with the systems and methods of the present disclosure.

[0033] In one embodiment, as shown in FIGS. 5A-5D, two or more potentials can be selectively applied to tool electrode 120 such that tool electrode 120 moves in a non-linear direction into workpiece 130. For clarity, various components from the electrochemical machining system 100 of FIGS. 5A-5D, including components such as power supply 170, controller 112, and actuator 113 (FIGS. 1 and 2), are omitted, and the electrochemical machining system 100 of FIGS. 5A-5D should be interpreted as including some or all of the features of the electrochemical machining system 100 of FIGS. 1-2. As generally shown in FIGS. 5A-5D, each of two or more individual electrodes 140 can have a unique potential with an accurately controlled voltage applied thereto, which are unique to each other and generate two or more electric fields 200 that oxidize workpiece 130 at different rates. Thus, it is possible to achieve not only the manufacture of parts having a reworked internal cavity 133, but also the manufacture of parts having complex shapes.

[0034] For example, as shown in FIG. 5A, the electrochemical machine is disposed at a first opening 132 of workpiece 130 where it is desirable to form a reworked internal cavity 133 (FIG. 5D). Next, as described herein, an electrochemical machining method can be performed, in which two or more potentials are applied to tool electrode 120 comprising an array of two or more individual electrodes 140 to generate two or more electric fields 200 between tool electrode 120 and workpiece 130 on the opposite side of tool electrode 120. As shown in FIGS. 5B and 5C, when the electrochemical machining method described by the present disclosure is performed, tool electrode 120 can move in a non-linear direction into workpiece 130 from the first opening 132 to the second opening 135. Thus, as shown in FIG. 5D, a workpiece 130 having a reworked internal cavity 133 can be formed. Further, the methods and systems described above with respect to non-linear electrochemical machining can be combined with other features described throughout the present disclosure, such as the delivery of a charged or uncharged electrolyte solution 142 through at least one electrolyte flushing port 146.

[0035] In another embodiment, as shown in FIG. 6, a method 700 for electrochemically machining a component is generally provided. The method includes a step 710 of applying two or more potentials to a tool electrode that includes an array of two or more individual electrodes to generate two or more electric fields between the tool electrode and a workpiece on the opposite side 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.

[0036] The step of applying two or more potentials to the tool electrode can be performed using a power supply. The configuration of the power supply to the array of two or more individual electrodes enables at least two of the two or more potentials to have different voltages from each other. Thus, in one embodiment, the two or more potentials can include a first potential and a second potential. In this regard, a potential specific to each of the two or more individual electrodes of the electrochemical machining system can be applied, and the oxidation rate of the workpiece can be individually controlled at strategic locations on the workpiece, so that the workpiece can be machined into a high-fidelity or sub-micron shape. Although shown as a single power supply in FIG. 1, the power supply may include two or more individual power supplies.

[0037] During operation, the workpiece can include a first electrode and a second electrode that can each individually function as a cathode, and can function as an anode of an array of two or more individual electrodes that generate two or more electric fields in which an electrolytic reaction occurs between the workpiece and the tool electrode.

[0038] The first potential and the second potential may be a specific pulse potential or, alternatively, a specific DC potential. In one embodiment, at least one of the first potential and the second potential is a DC potential in the range of 2 volts to 50 volts. In a further embodiment, at least one of the first potential and the second potential is a DC potential in the range of 12 volts to 35 volts.

[0039] In another embodiment, at least one of the first potential and the second potential is a pulsed potential. Specifically, the power supply may be configured to apply a pulsed potential to at least one of the first electrode and the second electrode. Further, the controller may be configured to adjust the pulse duration, frequency, and voltage of the pulsed potential supplied to the tool electrode and the workpiece. In a further embodiment, the pulsed potential may be a bipolar pulsed potential.

[0040] For example, the pulse duration of the pulsed potential may be from 10 nanoseconds to 500 microseconds. Further, in one embodiment, the pulsed potential may be applied at a voltage from 2 volts to 35 volts, such as from 5 volts to 15 volts.

[0041] As used herein, the term "average potential" is the average of the off-time potential and the on-time potential of each pulsed potential. In some embodiments, the average potential of the pulsed potential may be in the range of 5 volts to 32 volts.

[0042] Referring again to FIG. 6, the method may further include step 720 of delivering a charged or uncharged electrolyte solution to the electrochemical machining through at least one of the electrolyte flushing ports. When an uncharged electrolyte solution is delivered, oxide substances are washed away from the workpiece, improving the accuracy of electrochemical oxidation, and when a charged electrolyte is delivered, the additional advantage is obtained that two or more electric fields interfering with each other can be locally protected. For example, the power supply may include an auxiliary power supply (not shown) electrically connected to at least one electrolyte flushing port on the tool electrode. The auxiliary power supply can supply at least one charging port potential to at least one electrolyte flushing port. For example, the at least one charging port potential may have an applied voltage of 1 volt to 20 volts (positive) with respect to the applied machining voltage (i.e., two or more potentials).

[0043] In one embodiment, the method of the present disclosure further includes step 730 of electrochemically machining the workpiece such that the minimum dimension is less than 2 μm. In a further embodiment, the method of the present disclosure further includes a step of electrochemically machining the workpiece such that the minimum dimension is less than 1 μm.

[0044] In an exemplary embodiment, a charged or uncharged electrolyte solution is delivered into the electrochemical machining system from at least one of the at least one electrolyte flushing port at a rate of from 1 L / min to 50 L / min, such as from 1 L / min to 25 L / min, such as from 1 L / min to 10 L / min, such as from 1 L / min to 5 L / min.

[0045] Optionally, in combination with the delivery of the charged or uncharged electrolytic solution, the electrolyte solution can be continuously pushed into the electrode gap to wash the workpiece and the tool electrode at a flow rate of from 0.5 L / sec to 20 L / sec, such as from 3.75 L / sec to 10 L / sec. Further, the electrolyte solution can be continuously pushed into the electrode gap at a pressure of from 350,000 Pa to 3,500,000 Pa.

[0046] Furthermore, in some embodiments, the method includes a step of controlling the distance between the tool electrode and the workpiece (i.e., the length of the electrode gap) to be greater than 0.05 millimeters, such as greater than 0.1 millimeters. In some embodiments, the method includes a step of controlling the distance between the tool electrode and the workpiece to be from 0.1 millimeters to 2 millimeters, such as from 0.5 millimeters to 1.5 millimeters.

[0047] Aspects of the present disclosure relate to an electrode configuration incorporating an array of electrodes rather than a solid monolith. By incorporating an array of electrodes, the oxidation rate of the workpiece can be accurately closed-loop controlled at strategic locations on the workpiece. Specifically, by controlling the individual potentials applied to each individual electrode of the array of electrodes as compared to applying a single potential to a solid monolith, many advantages are obtained, such as being able to manufacture components with improved geometric fidelity using an electrochemical machining method that includes components with complex textures or low-rigidity structures.

[0048] Accordingly, the methods and systems described herein enable the electrochemical machining of a workpiece to have submicron features across a wide range of chemical properties of the workpiece. Further, the methods described herein are automated and have the advantage of being adjustable in real time because the potential applied to each individual electrode can be adjusted as desired during electrochemical machining. The present disclosure further incorporates the function of delivering the electrolyte and adjusting specific applied potentials to achieve components having high-quality surfaces and submicron dimensions. By actively controlling the potential and fluid delivery, it is also possible to manufacture components including non-linear shaped parts or parts made of high-temperature metal alloys that are prone to oxidation. Further, at least one electrolyte flushing port in the tool electrode array of the present disclosure can eliminate the need for a conventional flow box for controlling where and how the electrolyte flows between the tool electrode and the workpiece.

[0049] Furthermore, in electrochemical machining applications using a small electrode gap, the associated time constant for locally confining the reaction is 10 nanoseconds or less (e.g., from 1 nanosecond to 10 nanoseconds). Thus, when performing electrochemical machining using an array of two or more individual electrodes, improvements are obtained that overcome the signal attenuation and impedance problems when operating a monolithic tool electrode at high frequencies. In this regard, the methods and systems of the present disclosure can provide the ability to manage individual portions of the overall electric field (i.e., a combination of two or more electric fields) without sacrificing the stability or cycle time of the overall process.

[0050] A further aspect of the present invention is provided by the subject matter of the following clauses.

[0051] A method of electrochemically machining a component, the method comprising applying two or more potentials to a tool electrode including an array of two or more individual electrodes to generate two or more electric fields between the tool electrode and a workpiece on the opposite side of the tool electrode, each of the two or more electric fields being generated by one of the array of two or more individual electrodes.

[0052] The method according to any one of the clauses herein, wherein at least one spacer is disposed between a first electrode and a second electrode of the array of two or more individual electrodes.

[0053] The method according to any one of the clauses herein, wherein the at least one spacer has a thickness in the range of a few micrometers to 2500 micrometers.

[0054] The method according to any one of the clauses herein, further comprising delivering a charged or uncharged electrolyte solution between the tool electrode and the workpiece through at least one electrolyte flushing port in the at least one spacer.

[0055] The method according to any one of the clauses herein, wherein the two or more potentials include a first potential and a second potential.

[0056] The method according to any one of the clauses herein, wherein at least one of the first potential and the second potential is a direct current potential in the range of 12 volts to 35 volts.

[0057] The method according to any one of the clauses herein, wherein at least one of the first potential and the second potential is a pulsed potential.

[0058] The method according to any one of the clauses herein, wherein the pulsed potential has an average potential in the range of 5 volts to 32 volts.

[0059] The method according to any one of the clauses in this specification, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.

[0060] The method according to any one of the clauses in this specification, wherein at least one of the workpiece and the array of two or more individual electrodes contains a metallic material, and the metallic material includes a metallic alloy containing a titanium-based alloy, a niobium-based alloy, a nickel-based alloy, a zirconium-based alloy, an aluminum-based alloy, a palladium-based alloy, a platinum-based alloy, a titanium aluminide alloy, or a combination thereof.

[0061] The method according to any one of the clauses in this specification, wherein the component is an airfoil on a bladed disk.

[0062] The method according to any one of the clauses in this specification, further comprising the step of electrochemically machining the workpiece to have a minimum dimension of less than 2 μm.

[0063] The method according to any one of the clauses in this specification, wherein the electrolyte solution intervening between the tool electrode and the workpiece contains an aqueous salt electrolyte, and the aqueous salt electrolyte includes sodium nitrate, sodium chloride, sodium bromide, or a combination thereof.

[0064] The method according to any one of the clauses in this specification, wherein the step of applying two or more potentials to the tool electrode is selectively executed such that the tool electrode moves in a non-linear direction within the workpiece.

[0065] An electrochemical machining system comprising a tool electrode including an array of two or more individual electrodes, wherein when two or more potentials are applied to the array of two or more individual electrodes, two or more electric fields are generated between the tool electrode and the workpiece, and each of the two or more electric fields is generated by one of the array of two or more individual electrodes.

[0066] An electrochemical machining system according to any one of the clauses herein, wherein at least one spacer is disposed between a first electrode and a second electrode of an array of two or more individual electrodes.

[0067] An electrochemical machining system according to any one of the clauses herein, wherein at least one spacer comprises at least one electrolyte flushing port.

[0068] An electrochemical machining system according to any one of the clauses herein, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.

[0069] An electrochemical machining system according to any one of the clauses herein, wherein two or more potentials include a first potential and a second potential.

[0070] An electrochemical machining system according to any one of the clauses herein, further comprising a controller configured to independently control the first potential and the second potential.

[0071] This written description uses exemplary embodiments to disclose the invention, including the best mode, and to enable one of ordinary skill in the art to practice the invention, including making and using any device or system and performing any incorporated methods. The patentable scope of the present invention is defined by the claims, and other examples that occur to one of ordinary skill in the art may be included. Such other examples are within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with no substantial difference from the literal language of the claims.

[0072] Further aspects of the present invention are provided by the subject matter of the following clauses.

[0073] [Item 1] A method for electrolytically processing a component, comprising the step of applying two or more potentials to a tool electrode including an array of two or more individual electrodes to generate two or more electric fields between the tool electrode and a workpiece on the opposite side of the tool electrode, wherein each of the two or more electric fields is generated by one of the arrays of two or more individual electrodes.

[0074] [Item 2] The method according to any preceding item, wherein at least one spacer is disposed between a first electrode and a second electrode of the array of two or more individual electrodes.

[0075] [Item 3] The method according to any preceding item, wherein the at least one spacer has a thickness of from 100 micrometers to 2500 micrometers.

[0076] [Item 4] The method according to any preceding item, further comprising the step of delivering a charged or uncharged electrolyte solution between the tool electrode and the workpiece through at least one electrolyte flushing port in the at least one spacer.

[0077] [Item 5] The method according to any preceding item, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.

[0078] [Item 6] The method according to any preceding item, wherein the two or more potentials include a first potential and a second potential.

[0079] [Item 7] The method according to any preceding item, wherein at least one of the first potential and the second potential is a DC potential in the range of 12 volts to 35 volts.

[0080] [Item 8] The method according to any preceding item, wherein at least one of the first potential and the second potential is a pulsed potential.

[0081] [Item 9] The method according to any preceding item, wherein the pulsed potential has an average potential of from 5 volts to 32 volts.

[0082] [Item 10] At least one of the workpiece and the array of two or more individual electrodes includes a metallic material, and the metallic material includes a metal alloy including a titanium-based alloy, a niobium-based alloy, a nickel-based alloy, a zirconium-based alloy, an aluminum-based alloy, a palladium-based alloy, a platinum-based alloy, a titanium aluminide alloy, or a combination thereof, according to any of the preceding items.

[0083] [Item 11] The method according to any of the preceding items, wherein the component is an airfoil on a bladed disk.

[0084] [Item 12] The method according to any of the preceding items, further including the step of electrochemically machining the workpiece so as to have a minimum dimension of less than 2 μm.

[0085] [Item 13] The method according to any of the preceding items, wherein the electrolyte solution intervening between the tool electrode and the workpiece includes an aqueous salt electrolyte, and the aqueous salt electrolyte includes sodium nitrate, sodium chloride, sodium bromide, or a combination thereof.

[0086] [Item 14] The method according to any of the preceding items, wherein the step of applying two or more potentials to the tool electrode is selectively performed such that the tool electrode moves in a non-linear direction into the workpiece.

[0087] [Item 15] An electrochemical machining system including a tool electrode including an array of two or more individual electrodes, wherein when two or more potentials are applied to the array of two or more individual electrodes, two or more electric fields are generated between the tool electrode and the workpiece, and each of the two or more electric fields is generated by one of the array of two or more individual electrodes.

[0088] [Item 16] The electrochemical machining system according to any of the preceding items, wherein at least one spacer is disposed between a first electrode and a second electrode of the array of two or more individual electrodes.

[0089] [Item 17] The electrochemical machining system according to any of the preceding items, wherein at least one spacer includes at least one electrolyte flushing port.

[0090] [Item 18] The electrolytic processing system according to any one of the preceding items, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.

[0091] [Item 19] The electrolytic processing system according to any one of the preceding items, wherein two or more potentials include the first potential and the second potential.

[0092] [Item 20] The electrolytic processing system according to any one of the preceding items, further comprising a controller configured to independently control the first potential and the second potential.

Explanation of Signs

[0093] 100 Electrolytic processing system 112 Controller 113 Actuator 120 Tool electrode 130 Workpiece 140 Individual electrode 141 Electrolyte flushing channel 142 Charged or uncharged electrolyte solution 143 First electrode 144 Second electrode 146 Electrolyte flushing port 160 Spacer 170 Power supply 180 Electrode gap 190 Electrolyte solution 200 Electric field 400 Computing system 402 Computing device 404 Processor 406 Memory device 408 Computer-readable instruction 410 Data 412 Network interface, communication interface

Claims

1. A method for electrochemically machining a component, comprising: applying two or more potentials to a tool electrode including two or more individual electrodes to generate two or more electric fields between the tool electrode and a workpiece on the opposite side of the tool electrode, each of the two or more electric fields being generated by one of the two or more individual electrodes, and at least one spacer being disposed between a first electrode and a second electrode of the two or more individual electrodes; delivering a charged or uncharged electrolyte solution between the tool electrode and the workpiece through at least one electrolyte flushing port in the at least one spacer; A method comprising the steps of:

2. The method according to claim 1, wherein the at least one spacer has a thickness in the range of 100 micrometers to 2500 micrometers.

3. The method according to claim 1, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.

4. The method according to claim 1, wherein the two or more potentials include a first potential and a second potential.

5. The method according to claim 4, wherein at least one of the first potential and the second potential is a direct current potential in the range of 12 volts to 35 volts.

6. The method according to claim 4, wherein at least one of the first potential and the second potential is a pulsed potential.

7. The method according to claim 6, wherein the pulsed potential has an average potential in the range of 5 volts to 32 volts.

8. The method according to claim 1, wherein at least one of the workpiece and the two or more individual electrodes includes a metallic material, the metallic material including a metallic alloy including a titanium-based alloy, a niobium-based alloy, a nickel-based alloy, a zirconium-based alloy, an aluminum-based alloy, a palladium-based alloy, a platinum-based alloy, a titanium aluminide alloy, or a combination thereof.

9. The method according to claim 1, wherein the component is an airfoil on a bladed disk.

10. The method according to claim 1, further comprising electrochemically machining the workpiece with an accuracy of less than 2 micrometers.

11. The method according to claim 1, wherein the electrolyte solution intervening between the tool electrode and the workpiece includes an aqueous salt electrolyte, the aqueous salt electrolyte including sodium nitrate, sodium chloride, sodium bromide, or a combination thereof.

12. The method according to claim 1, wherein the step of applying two or more potentials to the tool electrode is selectively performed such that the tool electrode moves in a non-linear direction into the workpiece.

13. A tool electrode including two or more individual electrodes, wherein when two or more potentials are applied to the two or more individual electrodes, two or more electric fields are generated between the tool electrode and the workpiece, and each of the two or more electric fields is generated by one of the two or more individual electrodes. comprising at least one spacer is disposed between a first electrode and a second electrode of the two or more individual electrodes. The electrochemical machining system, wherein the at least one spacer includes at least one electrolyte flushing port.

14. The electrochemical machining system according to claim 13, wherein the first electrode and the second electrode are electrically connected in parallel with the workpiece.

15. The electrochemical machining system according to claim 13, wherein the two or more potentials include a first potential and a second potential.

16. The electrochemical machining system according to claim 15, further comprising a controller configured to independently control the first potential and the second potential.

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