Experimental Research on the Electrochemical Machining of Modern Titanium- and Nickel-based Alloys for Aero Engine Components

In order to increase the efficiency of jet engines hard to machine titanium- and nickel-based alloys are in common use for blade and disk materials. With Electrochemical Machining (ECM) highest material removal rates can be achieved at best surface qualities. However for tool design, knowledge of local material dissolution is indispensable. This paper deals with basic research on the electrochemical machinability of selected modern titanium- and nickel-based alloys for aero engine components. Therefor experimental results of feed rate as a function of current density for an ECM sinking operation with a cylindrical tool electrode and external flushing are compared to the theoretical dissolution behavior according to Faraday's law. Furthermore surface properties were examined in terms of SEM and EDX analysis of the rim zone.