Electrochemical drilling of ultra-high aspect ratio holes by magnetic alignment

PI: Sheng Shen

Co-PI(s): Burak Ozdoganlar

University: Carnegie Mellon University

Industry partner: Tech Met, Inc.

High-aspect-ratio, miniature holes on metal alloys find applications in many advanced systems. In this project, CMU is teaming with TECH MET Inc. to propose the use of shaped-tube electrochemical drilling with a novel magnetic alignment concept to enable drilling precise holes with ultra-high aspect ratios on hard-to-machine alloys. Our approach will involve a synergistic combination of experimental and modeling/simulation studies, aiming at understanding the relationship between process parameters and outcomes, including maximum achievable hole depth, hole-quality metrics, and material removal rate. Our approach will bring revolutionary advances to the state-of-the-art in making high-aspect-ratio, precise holes in alloys and will uniquely enable creating nuclear thermal propulsion for space missions and a range of applications in the energy sector.