Abstract: An electrode applied in electro-machining processes is provided. The electrode comprises a main body portion and at least one built-in internal flushing passage for introducing a flushing liquid to a volume between the electrode and a workpiece to be machined. The electrode is made by an additive fabrication process that enables specialized flushing for enhancing waste material evacuation and incorporate special material properties like zones of high electrical conductivity and thermal resistance. The fabrication process produces materials and geometries that could not otherwise be made using conventional processing.

Abstract: A method of manufacturing a component comprises forming a component on a conductive build plate. The component defines at least one access port and includes an inner surface that defines at least one internal passage. The method further includes forming at least one electrode within the at least one internal passage, wherein the at least one electrode is electrically isolated from the component. An electromotive force is applied to the at least one electrode to facilitate smoothing the inner surface.

Abstract: An electrochemical grinding tool and method capable of rounding sharp edges that may be prone to cracking, for example, edge regions of cooling slots within dovetail slots of turbine wheels. The electrochemical grinding tool includes a drilling assembly, a conductive bit, and a motor for rotating the conductive bit about an axis thereof. The conductive bit of the electrochemical grinding tool is inserted into a first slot, an electrolyte solution is applied between the conductive bit of the electrochemical grinding tool and a second slot that intersects the first slot, an electrical potential is applied to the conductive bit and the turbine wheel to create a potential gradient between the conductive bit and the edge of the second slot, and material is removed from the edge of the second slot by displacing the conductive bit about and along the edge.

Abstract: An electrochemical grinding tool and method capable of rounding sharp edges that may be prone to cracking, for example, edge regions of cooling slots within dovetail slots of turbine wheels. The electrochemical grinding tool includes a drilling assembly, a conductive bit, and a motor for rotating the conductive bit about an axis thereof. The conductive bit of the electrochemical grinding tool is inserted into a first slot, an electrolyte solution is applied between the conductive bit of the electrochemical grinding tool and a second slot that intersects the first slot, an electrical potential is applied to the conductive bit and the turbine wheel to create a potential gradient between the conductive bit and the edge of the second slot, and material is removed from the edge of the second slot by displacing the conductive bit about and along the edge.

Abstract: An electrochemical machining tool and method capable of rounding sharp edges that may be prone to cracking, for example, edge regions of cooling slots within dovetail slots of turbine wheels. The electrochemical machining tool includes an electrode and is secured to the component. The electrode of the electrochemical machining tool is inserted into a first slot, an electrolyte solution is applied between the electrode of the electrochemical machining tool and a second slot that intersects the first slot, an electrical potential is applied to the electrode and the turbine wheel to create a potential gradient between the electrode and the edge of the second slot, and material is removed from the edge of the second slot by displacing the electrode about and along the edge.

Abstract: A system for repairing a component is provided. The system includes an electrochemical machining unit and a tool delivery apparatus. The electrochemical machining unit includes an electrode, a power supply configured to energize the electrode and the component, and a machining solution source configured to pass a machining solution between the component and the electrode. The tool delivery apparatus includes a number of linkage elements pivotally connected and configured to carry the electrode. The tool delivery apparatus further includes an actuation element configured to actuate the linkage elements to move the electrode. A tool delivery apparatus and a method for repairing a component disposed within a case are also presented.

Abstract: An electroerosion machining system comprises one or more electrodes configured to machine a workpiece, a power supply configured to energize the workpiece and the respective one or more electrodes, an electrolyte supply configured to pass an electrolyte, and a working apparatus configured to move the respective one or more electrodes relative to the workpiece. The electroerosion machining system further comprises a controller configured to control the working apparatus to machine the workpiece, and a removal agent configured to cooperate with the electrolyte from the electrolyte supply for removal of removed material from the workpiece. An electroerosion machining method is also presented.

Abstract: A method for surface roughening a metal work piece includes disposing a region of the workpiece to be roughened proximate to a counter electrode. The region of the workpiece to be roughened and the counter electrode are subsequently disposed together in an electrolyte. An electric potential with current flow is applied between the work piece and the counter electrode to roughen the metal surface to a desired roughness.

Abstract: An apparatus and method for hybrid machining a workpiece is disclosed. The workpiece is powered as an anode, a cutter is powered as a cathode and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material. The hybrid machine performs a roughing pass machining operation in which material is removed from the workpiece at a relatively high rate using a high-speed electro-erosion (HSEE) process. Then, the hybrid machine performs a finish pass machining operation in which material is removed from the workpiece using precision electro-grinding (PEG) process at a different differential electrical potential and/or flushing rate than the roughing pass machining operation to provide a smooth finish without thermal effects on the workpiece.

Abstract: A method for altering a dimension of an element made of an amorphous metallic material is provided. The method includes providing an anode comprising the amorphous metallic material, wherein the amorphous metallic material comprises at least two primary constituents, providing a cathode disposed in a spaced-apart relationship with the anode, providing an electrolyte in contact with the anode and the cathode, and applying an electrical potential between the anode and the cathode.

Abstract: An apparatus and method for hybrid machining a workpiece is disclosed. The apparatus includes a mandrel for supporting the workpiece adjacent a cutter mounted on an arbor. A workpiece is powered as an anode and the cutter is powered as a cathode, and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material to maximize the amount of material removed from the workpiece. The coolant includes one or more additives to enhance the electrical discharge between the cutter and the workpiece. The cutter is moved relative to the workpiece to remove material from the workpiece at a predetermined depth of cut using an enhanced high-speed electro-erosion (HSEE) process in which both HSEE and abrasive machining processes are used. The workpiece may then be finish machined to a final shape of the titanium article, such as a dovetail of a turbine blade.

Abstract: An electrochemical grinding electrode comprises an electrically conductive material; an arc resistance material; and an abrasive material different from the arc resistance material. An electrochemical grinding apparatus and a method are also presented.

Abstract: An apparatus and method for hybrid machining a workpiece is disclosed. The workpiece is powered as an anode, a cutter is powered as a cathode and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material. The hybrid machine performs a roughing pass machining operation in which material is removed from the workpiece at a relatively high rate using a high-speed electro-erosion (HSEE) process. Then, the hybrid machine performs a finish pass machining operation in which material is removed from the workpiece using precision electro-grinding (PEG) process at a different differential electrical potential and/or flushing rate than the roughing pass machining operation to provide a smooth finish without thermal effects on the workpiece.

Abstract: An apparatus and method for hybrid machining a workpiece is disclosed. The apparatus includes a mandrel for supporting the workpiece adjacent a cutter mounted on an arbor. A workpiece is powered as an anode and the cutter is powered as a cathode, and a cutting fluid or coolant is circulated therebetween. The cutter is made of a conductive material and a non-conductive abrasive material to maximize the amount of material removed from the workpiece. The coolant includes one or more additives to enhance the electrical discharge between the cutter and the workpiece. The cutter is moved relative to the workpiece to remove material from the workpiece at a predetermined depth of cut using an enhanced high-speed electro-erosion (HSEE) process in which both HSEE and abrasive machining processes are used. The workpiece may then be finish machined to a final shape of the titanium article, such as a dovetail of a turbine blade.

Abstract: A method of forming a pattern comprising a plurality of recesses within a turbine component is disclosed. The method includes simultaneously dissolving a plurality of portions of a selected section of the turbine component, thereby defining the plurality of recesses of the pattern.

Abstract: A method for surface roughening a metal work piece includes disposing the work piece proximate to a counter electrode. The work piece and the counter electrode are disposed in an electrolyte. An electric potential with current flow is applied between the work piece and the counter electrode to roughen the metal surface to a desired roughness.