An efficient hybrid laser-electrochemical machining process for advanced materials

The introduction of new alloys with extreme properties along with a growing industrial demand towards fabrication of high aspect ratio meso/micro-dimensional features and micro-holes requires a substantial improvement of the process capabilities of existing micromachining processes. Further challenges are the requirements on high surface finish, high accuracy/tight tolerances and specific microstructures of the product. The idea behind hybrid micromachining is to combine different machining processes/material removal mechanisms to enhance the capability/performance of manufacturing these features with tighter specs while still reaching economic feasibility.
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 tool electrodes and laser optics, in order to improve the performance of the hybrid process. Furthermore advanced process monitoring techniques will be developed to study the fundamentals in material removal, whereby to increase the process efficiency and accuracy. The holistic approach in this project requires a broad range of expertise in combining, optical, electrochemical, thermal and CFD simulation techniques. The result will be an innovative and productive manufacturing technology for high-end components such as medical implants, high-temperature applications, or super-lubricated surfaces.