Reproduction of Three-Dimensional Microstructures on Inconel 718 Utilizing Laser-Textured PECM Cathodes

Abstract Pulse electrochemical machining (PECM) is an unconventional material removal process, widely applied to machine or shape difficult-to-machine materials. A new concept of reproducing three-dimensional (3D) microstructures has been developed and elaborated. Picosecond laser was utilized to produce concave or convex patterns on PECM cathodes, and pattern replication was carried out to PECM anodes. The laser achieved high machining precision and excellent surface integrity; both patterns were successfully replicated on the anodes. However, considerable deviations were found in the reproduced concave patterns on the anodes, possibly due to the rounding and widening effects.