Electrochemical Machining of Metal Plates
Electrochemical machining (ECM) with concentrated sodium chlorate electrolyte was used to rapidly cut a circular groove (13 cm diameter, 0.2 cm wide) through a 0.15 cm thick sheet of steel--thus opening a 5-inch porthole in as little as 10 minutes. The most favorable operating conditions were: T = 22 C; chlorate concentration 600 g NaClO{sub 3}/liter-solution; electric power of 100 A at 10 V; and flow of 0.5 l/s at a pressure drop of 10 kPa (1.5 psi). The porthole may be removed entirely by electrochemical means, or the electrochemical dissolution may continue until only thin membrane remains that is subsequently cut with a utility knife. An array of thermocouples was used to track temperature in the flowing solution and in the trough being machined; the maximum increase in temperature in the trough was 5 C over that of the flowing electrolyte which increased in temperature by 19 C because of power dissipation. ECM is shown feasible for rapid perforation of plates of ferrous and non-ferrous metals using portable equipment and commercial batteries. The technique can be extended to cut perforations of arbitrary shape through non-planar surfaces using a deformable ring cathode. Analysis of the power requirements for electrolyte flow and ECM indicate a total system weight of less than 45 kg (100 lb) using a commercial NiMH battery. The technique is recommended for reduction to practice and demonstration on full scale as an engineering prototype.
- Research Organization:
- Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
- Sponsoring Organization:
- US Department of Energy (US)
- DOE Contract Number:
- W-7405-ENG-48
- OSTI ID:
- 15015141
- Report Number(s):
- UCRL-TR-210474; TRN: US200509%%45
- Resource Relation:
- Other Information: PBD: 4 Mar 2005
- Country of Publication:
- United States
- Language:
- English
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