Novel Electrolytes for the Electrochemical Machining of Air-Breathing Propulsion Materials

Period of Performance: 11/18/1998 - 11/18/2000


Phase 2 SBIR

Recipient Firm

Eltron Research, Inc.
4600 Nautilus Court South
Boulder, CO 80301
Principal Investigator

Research Topics


This Phase II program is directed towards process optimization and hardware development of novel ElectroChemical Machining (ECM) technology identified during Phase I for achieving both the high rate and precision shaping of alloys, intermetallics and ceramic materials of relevance to Navy aircraft subsystems with minimal stray pitting. The approach is based upon the application of novel heterogeneous electrolytes which have been experimentally shown to enhance ECM performance. This proposed program will proceed by i) fabricating a prototype EMC machine, appropriate tools and software for implementing ECM using heterogeneous electrolytes ii) identifying preferred heterogeneous electrolytes for eliminating stray pitting, iii) performing a two level fractional factorial analysis of systematic experimental variables using the prototype ECM machine, iv) precision machining of Naval aircraft components, and v) developing commercial hardware. The approach is not expected to require significant modification of hardware used with current ECM technologies and consequently is fully expected commercially implementable during this program.