Electrochemical Jet Machining for Precision Micro manufacturing: Process Parameters, Performance Metrics, and Research Opportunities

Electrochemical Jet Machining (ECJM) is an emerging non-traditional machining process that removes electrically conductive material by localized anodic dissolution using a high-velocity electrolyte jet. Unlike conventional machines, the process is non-contact and does not rely on a solid cutting tool, making it attractive for precision micromanufacturing and difficult-to-machine materials. This paper presents a focused review of the operating principle of ECJM, its governing process parameters, performance measures, material compatibility, advantages, limitations, and recent research directions. Particular attention is given to machining voltage, electrolyte concentration, jet velocity, stand-off distance, nozzle geometry, current density, material removal rate, dimensional accuracy, and surface quality. The paper also discusses assisted variants and opportunities for inline sensing, data-driven process control, and sustainable electrolyte management. The review indicates that ECJM has strong potential for localized machine, micro-hole generation, surface texturing, and precision features, while process stability, lateral overcut, electrolyte handling, and scalable control remain important research challenges