Electro-Chemical Machining - it's like Magic

Electro-Chemical Machining (ECM) is the generic term for a variety of electro-chemical processes. ECM is used to machine workpieces through the anodic dissolution of metal. The process is used in aerospace engineering and the automotive, construction, medical equipment, microsystem and power supply industries. Almost all kinds of metal can be electro-chemically machined, especially high-alloyed nickel or titanium based ones, as well as hardened materials.
As it is a contactless procedure with no heat input, the process is not subject to any of the disadvantages experienced with traditional machining methods, e.g. tool wear, mechanical stresses, micro-fissures caused by heat transfer or the need for subsequent deburring operations. All electro-chemical machining processes are characterized by stress-free stock removal, gentle transitions and top-quality surfaces without burr formation.
Electro-Chemical Machining is based on the principle of electrolysis. Simon Popecki from EMAG explains to MTDCNC,s Tony Gunn the dark arts of these machines.
The tool, i.e. the cathode, is connected to a direct voltage source with the workpiece acting as the anode. A charge exchange takes place between the cathode and the anode in an aqueous electrolyte solution which targets specific areas of the workpiece. This can be used to create contours, ring ducts, grooves or bell hollows with no contact but very high precision. The removed material is precipitated from the electrolyte solution in the form of metal hydroxide. The machining can be carried out regardless of the structural condition of the metal and both soft and hard materials, including exotic metals, can be machined. This is a must watch video.
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[@250smacks]

Tooling (cathodes) can be designed and printed in pla. I just finished making a 357 mag rifling mandrel that holds copper wire. It’s 1-16 twist 6 grooves and 9 inches long.

[@IkarimTheCreature]

This is amazing!

[@jackjones9460]

What voltage and amperage is optimal? Does it matter what type of salt you use, maybe potassium nitrate instead of NaCl? Seems it’d be useful to produce fertilizer as a waste products instead of hazmat or poison.

[@ShitlordMcDoge]

The poison comes from the chrome in the alloy, not from the used salt