FREQUENTLY ASKED QUESTIONS

We combine the latest CNC machining and turning processes with proprietary technology to deliver high quality, on-demand parts.  Our typical tolerance accuracy ranges from  0.01mm  to 0.001mm  , depending on customer specs.

The internal contouring and overall shape complexity requirements of this industry’s products can be successfully met by pECM.

Application examples: petrochemical, oil & gas production (e.g., gas turbines, gas windmills, etc.), drilling installations, turbine engine components: fuel cells, valves, nozzles, and pumps.

  • Material selection and sourcing
  • Pattern development
  • Prototyping
  • Production
  • Heat Treatment
  • Quality Assurance 

Many of the processes which can be realized with conventional machining can be done so by pECM (e.g., milling, drilling, etc.), and in certain cases pECM can add accuracy or time optimization to those.

CARBON STEEL

HIGH-SPEED STEEL

CAST ALLOYS

CEMENTED TUNGSTEN CARBIDE

OXIDES

DIAMONDS

PECM is especially suitable for meeting this industry’s demand for machining complex geometries and new exotic alloys.

Application examples: turbine blades and blisks in jet engines and gas turbines, gears, nozzles, manifolds, diffusers, valves.

PROCESS ADVANTAGES

The advantages of pECM can be categorized by product, material and machine advantages.

  1. Product advantages:
  2. Excellent burr-free surface finish
  3. No mechanical or thermal load on the workpiece
  4. No upper layer deformation
  5. Full-form shaping (incl. 3D products) in a single step
  6. Generating complicated shapes and complex contours
  7. High machining speed at relatively low cost
  1. Material advantages:
  2. The material removal rate (MRR) is not influenced by the hardness, toughness, or thermal resistance of the material, and is in most cases independent on the type of material
  3. High material removal rate (MRR): approx. 1,5 cm³/min at 1000A DC
  4. The machining speed is independent on the type of material
  5. Material is dissolved and not cut
  1. Machine advantages:
  2. Cheaper on the long run thanks to the low recurring costs (as opposed to the higher initial investment)
  3. Almost no electrode wear
  4. Capable of creating micro structures
  5. High machining accuracy due to the superior process stability

/// PROCESS CONSIDERATIONS

  • PECM was previously known as harmful to the environment. However, the solution to this problem was introduced by including an Electrolyte Handling System in the electrolyte treatment process. Not only the process has become less harmful, but the produced sludge can nowadays be used as raw material with or without follow-up treatment. In addition, the electrolyte can be used almost indefinitely.
  • Each product and material require new R&D to be conducted. This can eventually extend the overall project time in its initial phase. However, through this highly customized procedure very accurate results can be expected.
  • The design of the electrode is a complex process and requires high initial investment. That is why the pECM technique is especially suitable for high volume production. The electrode can however be used nearly indefinitely, which makes the process more economically sustainable on the long run.
  • The power consumption necessary for the pECM process is relatively high. However, it remains much lower in comparison with other non-conventional machining techniques due to the fact that the pECM process operates at high current but relatively low voltage (5-15V).
  • The pECM process requires specialized technology skills and know-how, as well as extensive staff experience. Due to the innovative nature of the process, know-how can be acquired only through extensive working experience with the technology. Should you be interested in testing the pECM technology feasibility for your company products, here at ECM Technologies we offer the service of Consultancy & Training, where in-house professionals can share their expertise.