Development of a maskless electrochemical texturing method

A simple method is demonstrated for texturing metallic surfaces by electrochemical machining, termed ‘maskless electrochemical texturing’ (MECT). The method allows a single cathode tool, in which the texture is incorporated through a pattern of perforations, to be used for many texturing operations and avoids the need for masks to be applied to individual workpieces. It therefore has significant advantages over conventional methods of texturing by electrochemical machining. The method has been applied to low-carbon steel workpieces and features up to 50 μm in depth have been produced. Current efficiencies of more than 90% have been achieved, and the texturing time is short enough for application in an industrial context. The process has been characterised in terms of the effects of current pulse history and electrolyte flushing conditions on current efficiency, material removal rate and feature definition.