Jet-electrochemical machining of selective laser melted aluminum and steel alloys for micro injection moulds

For a flexible and resource efficient generation of moulds for micro-injection moulding, additive manufacturing processes such as Selective Laser Melting are used. Electrochemical machining (ECM) is a promising technique for the final shaping of the mould and for creation of the injection cavity with required precision, since ECM is independent of material hardness and ductility [1]. The latter property is important concerning SLM produced moulds, which are often harder and stronger than cast moulds. In this study, electrochemical machining of two SLM materials, AlSi10Mg Aluminium alloy and 18Ni-300 Nickel-based maraging tool steel, is analysed. A unique process applying a continuous electrolytic free jet (Jet-ECM) is used that offers the possibility to generate micro-structures by controlling the nozzle movement and the current flow.