An efficient hybrid laser-electrochemical micromachining technology

The idea behind hybrid micromachining is to combine different machining processes/material removal mechanisms to enhance the capability/performance of state of the art manufacturing processes while still reaching economic feasibility. Hybrid laser-electrochemical micromachining involves coaxial and concurrent application of electrochemical and laser processes in the same machining zone. This project will conduct in-depth research into the fundamentals of material removal in a new hybrid laser-electrochemical micromachining process by developing innovative solutions for the core components, such as hybrid machining head, tool electrodes and laser optics; in order to improve the performance of the hybrid process. The main goal here is to maximize laser fluence in the presence of electrolyte on the workpiece side to be able to broaden material processing window. Fundamental investigations on process-material interaction will be carried out in milling mode. Hardware modifications are foreseen as a part of project. The hybrid laser-ECM process together with machine kinematics will be used to demonstrate fabrication of cooling holes on superalloys with thermal barrier coatings. Delamination at the coating-metal interface will be studied using microscopic techniques. Multiphysics simulation framework will be developed to understand the coating delamination in presence of electrochemical and thermal process loads. Furthermore advanced process monitoring techniques such as high speed imaging will be employed to supplement the experiments on fundamentals of material removal and monitoring of by-product generation. The result will be an innovative and productive hybrid machining technology for high-end components such as turbine blades, medical implants, high-temperature applications, or super-lubricated surfaces.