Abstract: An electrode and method for the electrochemical machining of a workpiece is disclosed. The electrode is designed as a cathodically polarized tool electrode. It has a geometry that corresponds to the geometry to be removed from the workpiece, at least in a machining range, and perviousnesses in the electrode to allow an electrolyte to flow through and exit at the electrode surface, at least in the area of the machining range. The perviousnesses are formed by a porous design of the electrode and/or by artificially created openings in the electrode or the electrode surface. The porosity distribution and/or the number, arrangement and configuration of the openings is selected such that a uniform electrolyte flow and/or electrolyte exchange at the electrode surface is ensured at least in the machining range of the electrode.

Abstract: The invention relates to a method for producing and repairing a part comprising at least two joined metal components, especially components of a gas turbine. In said method, corresponding joining surfaces of the components are joined together and connected by means of a pressure welding process, a machining allowance in the area of a joining zone of the two joining surfaces is upset during the joining process, and once the two components have been joined together, the machining allowance is machined by means of a precise electrochemical machining (PECM) process until a predefined final contour of the part has been obtained. The invention further relates to a gas turbine part obtained by means of the disclosed method.

Abstract: A method for producing integrally bladed rotors comprises the following steps: a) defining and providing a blade profile of a blade to be manufactured with a pre-contour and a theoretical contour; b) producing at least two sectional planes of the blade profile, which sectional planes run vertically to a threading axis of the blade profile and of the blade to be manufactured; c) determining a point of rotation per sectional plane to produce an interval between the pre-contour and the theoretical contour that is approximately the same circumferentially, which points of rotation are located on a connecting line running parallel to the threading axis; and d) providing a base rotor body and electrochemically working the base rotor body in order to produce a raw blade with the blade pre-contour by movement of a hollow electrode into the base rotor body, the electrode movement including advancing motion along the connecting line superposed by rotation at the points of rotation, and which hollow electrode has an inne

Abstract: A method for removing material from a component that is connected as an anode is disclosed. In an embodiment, an electrode that is connected as a cathode is guided to the component such that a gap is formed, an electrolyte is introduced into the gap, and a closed system is formed for the electrolyte by the formation of a duct. The electrolyte is continuously guided from an inlet opening to an outlet opening of the duct. Forming the duct, e.g., by guide elements that are mounted on the electrode, ensures that only those surface parts of the component to be machined from which material is to be removed enter in contact with the electrolyte while the other surface parts do not enter in contact with the electrolyte. Since the electrolyte is continuously guided across the surface, used electrolyte is continuously discharged along with residual matter while fresh electrolyte is delivered.

Abstract: A method for producing a lightweight turbine blade for a gas turbine is disclosed. In an embodiment, the method includes casting of a blade element with a blade wall and at least one cavity enclosed by the blade wall. The blade wall is at least partially reduced in thickness by machining after the casting. This provides a method for producing a blade element, in which the wall thickness of the blade wall can be adapted to the mechanical load of the blade element, and the weight of the blade element can be reduced at the same time.

Abstract: A method for manufacturing gear wheels, specifically transmission gear wheels, is disclosed. An embodiment of the method includes the following steps: a) preparation of a base body for a gear wheel, b) electrochemical processing of the base body by a precise electrochemical machining process (PECM process), where several recesses running between the teeth of the gear wheel are made simultaneously electrochemically to manufacture the teeth of the gear wheel.

Abstract: The invention at hand relates to a method for processing and repairing a metal component with at least one finished or nearly finished partial component surface and at least one working surface to be further processed by means of an electrochemical treatment process and abutting the at least one finished or nearly finished partial component surface, with the process comprising the following steps: a) application of an electrically conductive layer on at least one area of the at least one finished or nearly finished partial component surface abutting the working surface to be processed, with the layer containing a metal or a metal alloy that has a similar or the same as, or a desiredly different electrochemical erosion behavior than the metal component; and b) electrochemical treatment of the working surface and of the layer, with the layer being completely or nearly completely eroded. The invention moreover relates to a component of a gas turbine or of a high or low pressure compressor.

Abstract: An electrode (10) is provided for electrochemical reduction of a workpiece (20) that is to be treated. The electrode (10) has a predefined contour and contains an electrically conductive material. The electrically conductive material of the predefined contour forms an electrode core (12). The outside of the electrode core (12) is covered with an insulation layer (13). The insulation layer (13) is porous and is made of an electrically non-conductive material.

Abstract: An electrode (10) is provided for electrochemical reduction of a workpiece (20) that is to be treated. The electrode (10) has a predefined contour and contains an electrically conductive material. The electrically conductive material of the predefined contour forms an electrode core (12). The outside of the electrode core (12) is covered with an insulation layer (13). The insulation layer (13) is porous and is made of an electrically non-conductive material.

Abstract: An electrode (10) is provided for electrochemical reduction of a workpiece (20) that is to be treated. The electrode (10) has a predefined contour and contains an electrically conductive material. The electrically conductive material of the predefined contour forms an electrode core (12). The outside of the electrode core (12) is covered with an insulation layer (13). The insulation layer (13) is porous and is made of an electrically non-conductive material.

Abstract: The invention relates to a method for the production of aero-dynamic structures during the production of integrally bladed gas turbine rotors. Aerodynamic structures of an integrally bladed gas turbine rotor are produced on a rotor disk base body, whereon the end contours are precise, by removing material according to an electrochemical removal process, i.e. by means of an electrochemical machining (ECM)-process. The method comprises the following steps: a) preparing a rotor disk base body which is made of a material which is difficult to machine; b) removing the material which is between the blade wings until a specific dimension is obtained, according to a removal process; c) preparing at least one working electrode in order to finish at least one aerodynamic structure of an integrally bladed gas turbine rotor.

Abstract: A method for applying hot gas anticorrosion layers to high-temperature-resistant alloys, either nickel-based or cobalt-based alloys, in the form of a gradient layer consisting of one or more elements of the platinum group in combination with aluminum. The components are introduced into a directional high-temperature, high-enthalpy, free jet of solid, liquid or gaseous precursors in mixing ratios such that defined concentration gradients can be established in the layer.

Abstract: A method for the selective removal of one or more layers from a power unit component, e.g., a turbine blade of a heavy-duty turbine, using high-energy radiation of such a wavelength that the supplied energy is so strongly absorbed by the layer to be removed in each case that the removal threshold of the specific material of the layer to be removed is exceeded, while this removal threshold is not reached in the subsurface to be preserved, a spectrometer connected to a control unit via a light-conducting fiber cable such that the method-specific characteristic values are determinable by spectroscopic methods during the removal of the respective layer and are used for the self-regulating process limitation.

Abstract: A method for electrochemically stripping components, especially gas turbine components, is provided. According to the method, the component from which a coating is to be removed is connected to a positive terminal of a voltage source or current source while an electrode is connected to a negative terminal thereof. An electrode is used that is precisely adapted to a region of the component to be stripped such that a gap between the region of the component to be stripped and the electrode is approximately constant over the entire region to be stripped.

Abstract: A method is disclosed for manufacturing blades arranged on the outside circumference of an impeller in a BLISK technology by contouring by means of an electrochemical machining method using molded cathodes. The surface of the blades in contouring is equipped with a negative structure in relation to the molded cathode surface and at the same time a structure that minimizes boundary layers in one manufacturing step. The electrochemical machining method is a pulsed method.

Abstract: A method for manufacturing components of a gas turbine includes at least the following steps: a) a component is produced using a metal injection molding process (MIM process); b) subsequently, the component produced using the metal injection molding process is machined to completion on its surface using a precise electrochemical machining process (PECM process).

Abstract: A method and device for the production of components having a three-dimensionally formed surface by a lowering operation with an electrochemical ablation process, namely a Precise Electro Chemical Machining (PECM) process, is disclosed. The method includes the steps of: a) providing a specially pre-formed workpiece featuring a specific dimensional allowance; b) providing at least one working electrode, in which case the contour of the working electrode, or of each working electrode, is adapted to the contour of the three-dimensionally formed surface to be produced; and c) lowering the three-dimensionally formed surface by placing the pre-formed workpiece and the working electrode, or each working electrode, in an electrolyte and by applying an electrical voltage or an electrical current, in which case the working electrode, or each working electrode, is moved in the sense of a circular advance motion in the direction toward the workpiece.

Abstract: A method for manufacturing integrally bladed rotors (preferably gas turbine rotors) is provided. The method includes the steps of a) providing a basic rotor body; b) placing the basic rotor body into an electrolyte; c) electrochemically machining the basic rotor body by simultaneously manufacturing a plurality of unmachined blades; and d) subsequently machining the unmachined blades to provide hydrodynamic surfaces, in particular a suction side and a pressure side, in the area of each unmachined blade.

Abstract: A method for machining workpieces provides a machining electrode, which is guided at a specific distance to the workpiece. An electrolyte is provided between the workpiece and the machining electrode, through which an operating current flows between the machining electrode and the workpiece. The operating current results from an operating voltage (UA), which is produced at the machining electrode, the workpiece being connected to ground. To perform the machining procedure, the distance between the machining electrode and the workpiece is regulated and the operating voltage (UA) is determined in such a way that the resulting operating current is a DC current or a pulsed DC current—i.e., the operating voltage is a DC voltage of fixed or specific dimension. A measuring voltage (UM) is superimposed on the operating voltage (UA) for producing the operating current.

Abstract: An electrode and method for the electrochemical machining of a workpiece is disclosed. The electrode is designed as a cathodically polarized tool electrode. It has a geometry that corresponds to the geometry to be removed from the workpiece, at least in a machining range, and perviousnesses in the electrode to allow an electrolyte to flow through and exit at the electrode surface, at least in the area of the machining range. The perviousnesses are formed by a porous design of the electrode and/or by artificially created openings in the electrode or the electrode surface. The porosity distribution and/or the number, arrangement and configuration of the openings is selected such that a uniform electrolyte flow and/or electrolyte exchange at the electrode surface is ensured at least in the machining range of the electrode.