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This section provides an overview for electrochemical machining as well as their applications and principles. Also, please take a look at the list of 8 electrochemical machining companies and their company rankings. Here are the top-ranked electrochemical machining companies as of December, 2024: 1.Superalloy Manufacturing Solutions Company, 2.Buchanan Sales Co., 3.Norwood Medical.
Table of Contents
Electrochemical machining is a method of machining by passing an electric current through a workpiece in an electrolytic solution to cause a chemical reaction.
It is also called ECM. When an electric current flows between the electrode (negative electrode) and the workpiece (positive electrode), the metal of the workpiece on the positive electrode turns into metal ions, which dissolve into the electrolytic solution.
The dissolved metal ions also produce other products (sludge, etc.) in the electrolyte. Hydrogen gas is produced at the anode. Using this series of electrochemical reactions, it is possible to transfer the shape of the electrode to the workpiece by machining the tool electrode very close to the surface of the workpiece.
Electrolytic machining is used to process parts that are difficult to machine, such as turbine blades in aero engines, and parts such as automobile engine parts, where burrs are not desired.
Electrochemical machining can be performed in two ways, depending on the accuracy of the process.
This is a method of electrochemical machining in which the workpiece metal is the positive electrode and the tool electrode is the negative electrode, and the distance between the electrodes is kept at a very close distance (usually 0.02 to 0.7 mm) in the electrolytic solution. The processing speed is extremely fast, taking only a few 10 seconds.
The process can be applied to hard metals that are difficult to process in the past. Also, complex shapes and holes that have been difficult to cut can be machined with high precision.
Precision electrochemical machining (PECM), which combines the flushing action of the tool electrode with a pulsed power supply, has been put to practical use for even higher precision machining.
In this method, the electrode or workpiece is vibrated up and down at high speed when the electrode is brought close to the workpiece, and products such as sludge are ejected at high speed and a fresh electrolytic solution is constantly supplied. In this process, the distance between the workpiece and the electrode is precisely controlled at around several tens of microns by a pulse power supply.
Electrochemical machining is capable of machining complex contours and cavities that are difficult to achieve with other machining methods, such as thin-walled features or downskin surfaces.
Difficult-to-cut materials can be machined much faster than with other machining methods. Furthermore, the customization of the tooling allows PECM to add tool surface area and machine multiple features in parallel in a way that conventional machining cannot achieve.
Non-contact machining has the advantage of not applying mechanical or thermal stress to the workpiece, allowing tight-tolerance machining to areas sensitive to thermal distortion or tool vibration, such as thin walls.
Because electrochemical machining is a chemical reaction process, it is possible to achieve a mirror finish on the surface, down to less than 0.5 μm Ra, and even down to 0.1μm Ra. Furthermore, on components that may require varied surface quality in different areas, PECM enables selective finishing in one singular machining process.
Brittle materials that are difficult to machine can be processed. Brittle materials are hard and brittle materials such as cemented carbide.
The disadvantage of electrochemical machining is that the electrolytic solution used for electrochemical machining is difficult to maintain uniformity, so the machining accuracy is unstable. It is also difficult to detect the distance between the workpiece and the electrode, and furthermore, the equipment needs to be treated for corrosion resistance. In addition, the product may be toxic.
Furthermore, compared to other conventional process, PECM has higher NRE costs, as developing the ideal cathode (tool) is a complex engineering challenge and therefore requires multiple iterations of part design and testing. This high initial investment, however, is outweighed if the project requires high part volumes.
Electrochemical machining is performed by using an electrolytic solution, which not only conducts electricity but also cools the workpiece. Additionally, the electrolytic fluid functions as the flushing agent that removes waste material from the workpiece.If the amount of electrolyte is too small, the finished product may vary, while too much electrolyte may cause discoloration. It is necessary to maintain an appropriate amount of liquid for processing.
Three types of electrolytic solutions are used: neutral salt solution, acid solution, and alkali solution.
Neutral Salt Solution
This is the most commonly used electrolyte. It has lower conductivity than alkaline solutions, but is less corrosive and can be used for most metallic materials. Sodium chloride electrolyte is commonly used. This electrochemical machining accuracy can occur because it is difficult to achieve a uniform concentration in the solution.
In some cases, sodium chlorate or sodium nitrate is used as the electrolyte. However, although processing accuracy improves, current efficiency decreases, resulting in increased power consumption.
Acid Solution
Acid solutions are electrolytes that require careful handling and are used in special cases. It has relatively high conductivity, but it is highly corrosive and conductivity decreases after prolonged use.
Alkali Solution
Alkaline solution is an electrochemical machining solution for cemented carbide. It is used for processing tungsten and molybdenum. For cemented carbides, it provides a better quality finish than neutral salt solutions.
It is not used for common metals because insoluble products are generated during machining, preventing the elution of the workpiece.
Citations
https://www.voxelinnovations.com/post/pecm-and-next-gen-manufacturing
https://www.voxelinnovations.com/post/ecm-surface-quality
https://ssw-americas.com/electrochemistry-as-machining-pecm-and-its-applications/
*Including some distributors, etc.
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Norwood Medical is a manufacturer of medical devices, founded in 1920, located in Ohio, USA. The company produces complex surgical devices for pioneering companies in the medical industry, primarily for arthroscopic procedures, spinal procedures, trauma surgery, and joint reconstruction. Its products play a pivotal role in advancing procedural advancements in orthopedic care, ultimately improving the lives and well-being of patients. The company's strict quality control and risk management help ensure that the instruments and procedures manufactured meet the highest standards for safety and efficacy.
Superalloy Manufacturing Solutions Company is a manufacturer of turnkey components, established in the 1980s and headquartered in Cincinnati, United States of America. The company crafts integrally bladed rotors, cases and structures, as well as blades or vanes. Its integrally bladed rotors have diameters from 3” up to 52”, maximum twists of 70 degrees, minimum airfoil spacings of .110", and minimum leading and trailing edge thicknesses of .01". It serves space, industrial, aerospace, and oil and gas markets.
AMETEK Scientific Instruments is based in Oak Ridge, Tennessee, USA, and is an ISO 9001-certified manufacturer of precision analysis instrumentation established in 2006 as a division of AMETEK, Inc. The company produces professional electrochemical, corrosion, and material analysis instruments. These include photoelectrochemical test systems used in solar cell research, frequency response analyzers, and energy storage testing products. The company’s products are mainly used by clients in the research, power generation, and petrochemical sectors.
EMAG GmbH & Co. KG, established in 1867 and headquartered in Salach, Baden-Württemberg, Germany, is a manufacturer and supplier of machining solutions for the metalworking sector. The company's product range includes turning, milling, grinding, hobbing, and laser welding technologies. These tools are applied in sectors such as automotive, oil field, power generation, and aerospace. The company supports the production of components for transmissions, engines, and chassis, as well as specialized components for the oilfield and aerospace industries. It also offers services like service contacts, smart services, retrofitting, and customer training.
Extrude Hone AFM (Extrude Hone), founded in 1971 with headquarters in the Greater Los Angeles Area, USA, since 1991, is a manufacturer of small batch components and prototypes and a supplier of state-of-the-art finishing technologies. The company's finishing technologies for various equipment include fuel systems; friction, wear, and noise reduction in transmission; turbine performance; and extended life of components. All component prototypes and small batch runs are custom-manufactured for client-specific requirements and fully tested for performance. Madison Industries completed the acquisition of the Extrude Hone business from Kennametal in 2015.
Ranking as of December 2024
Derivation Method| Rank | Company | Click Share |
|---|---|---|
| 1 | Superalloy Manufacturing Solutions Company |
24.8%
|
| 2 | Buchanan Sales Co. |
17.8%
|
| 3 | Norwood Medical |
16.8%
|
| 4 | MICRO |
15.0%
|
| 5 | Extrude Hone |
12.6%
|
| 6 | AMETEK Scientific Instruments |
7.0%
|
| 7 | EMAG GmbH & Co. KG |
5.6%
|
| 8 | Nissho Astec Co., Ltd. |
0.5%
|
Derivation Method
The ranking is calculated based on the click share within the electrochemical machining page as of December 2024. Click share is defined as the total number of clicks for all companies during the period divided by the number of clicks for each company.Number of Employees
Newly Established Company
Company with a History
*Including some distributors, etc.
*Including some distributors, etc.
| Country | Number of Companies | Share (%) |
|---|---|---|
|
United States of America
|
4 | 80.0% |
Japan
|
1 | 20.0% |
