Electrochemical jet manufacturing technology: From fundamentals to application

Speidel, Alistair; Bisterov, Ivan; Saxena, Krishna Kumar; Zubayr, Mohamed; Reynaerts, Domeniek; Natsu, Wataru; Clare, Adam T.

doi:10.1016/j.ijmachtools.2022.103931

Cited by 44 publications

(5 citation statements)

References 221 publications

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“…These are the key characteristics, along with the nozzle diameter, that dictate the scale of features in conventional electrochemical jet processing. [ 54 ] Thus, a facile mechanism through which morphology can be modulated can be realized through parameter selection. Increasing jet impingement velocity leads to a finer distribution of well‐defined channels, while material removal increases with greater current densities and lower feed rates evidenced by deeper channels.…”

Section: Resultsmentioning

confidence: 99%

Direct Writing Unclonable Watermarks with an Electrochemical Jet

Speidel

Bisterov

Clare

2022

Adv Funct Materials

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Counterfeit parts result in significant losses per annum and are often dangerous, therefore they represent a serious concern for manufacturers and end users alike. Easily written but unclonable watermarks undermine the proposition of the counterfeiter. Here, a rapid electrochemical jet engraving routine is presented to encode robust materials with self-organized dendritic structures at length scales that can be imaged with a smartphone. Surface defects act as stochastically distributed seeds from which discrete pitting events can be propagated by translating the electrochemical field. While the vascular pathways can be directly written at the macro scale, the formation and propagation of microscale dendritic arms is chaotic, caused by the implicit randomness of the defect seeds and the supply of ions to the surface. The latter is confounded by random perturbations in the flow condition. Each engraved dendrite is unique, stable at high temperature (>500 °C) and can be subjected to rapid image recognition to allow individual mark identification at any point during part production and delivery, or through part lifetime.

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Section: Resultsmentioning

confidence: 99%

Direct Writing Unclonable Watermarks with an Electrochemical Jet

Speidel

Bisterov

Clare

2022

Adv Funct Materials

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“…Jet-ECM technology has been developed in parallel for micro-scale processing, and it has been reviewed extensively in ref. (Speidel et al, 2022). The electrochemical jets can be created in varying diameters depending on the nozzle diameter and current density can be manipulated through nozzle shape (Mitchell-Smith et al, 2017).…”

Section: Nozzles For Jet-ecm Micro-processingmentioning

confidence: 99%

Tooling aspects of micro electrochemical machining (ECM) technology: Design, functionality, and fabrication routes

Liu,

Karim,

Arshad

et al. 2023

Journal of Materials Processing Technology

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“…Therefore, Jet-ECM has been highly used by researchers and engineers. Its fundamental theories, key technologies, and potential application development have been well studied [ 40 , 41 , 42 ]. Kawanaka et al [ 39 ] achieved a mirror-like micro-pit structure on a stainless steel workpiece using Jet-ECM with bipolar pulse current.…”

Section: Introductionmentioning

confidence: 99%

Microfabricating Mirror-like Surface Precision Micro-Sized Amorphous Alloy Structures Using Jet-ECM Process

Han,

Ming,

Niu

et al. 2024

Micromachines

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Amorphous alloy (AA) is a high-performance metal material generally with significantly excellent mechanical and corrosion resistance properties and thus is considered as a desirable material selection for micro-scale articles. However, the microfabrication of AA still faces a variety of technical challenges mainly because the materials are too hard to process and easily lose their original properties, although at moderately high temperatures. In this study, jet-electrolyte electrochemical machining (Jet-ECM) was proposed to microfabricate the Zr-based AA because it is a low-temperature material-removal process based on the anode dissolution mechanism. The electrochemical dissolution characteristics and material removal mechanism of AA were investigated, and then the optimal process parameters were achieved based on the evaluation of the surface morphologies, surface roughness, geometrical profile, and machining accuracy of the machined micro-dimples. Finally, the feasibility was further studied by using Jet-ECM to fabricate arrayed micro-dimples using the optimized parameters. It was found that Jet-ECM can successfully microfabricate mirror-like surface AA arrayed precision micro-dimples with significantly high dimensional accuracy and geometrical consistency. Jet-ECM is a promisingly advantageous microfabrication process for the hard-to-machine AA.

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Electrochemical jet manufacturing technology: From fundamentals to application

Cited by 44 publications

References 221 publications

Direct Writing Unclonable Watermarks with an Electrochemical Jet

Direct Writing Unclonable Watermarks with an Electrochemical Jet

Tooling aspects of micro electrochemical machining (ECM) technology: Design, functionality, and fabrication routes

Microfabricating Mirror-like Surface Precision Micro-Sized Amorphous Alloy Structures Using Jet-ECM Process

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