ELECTROSTREAM DRILLING

Electrostream (ES) (capillary) drilling is a special ECM technique used for producing fine holes
that are too deep to produce by EDM and too small to drill by STEM. The cathodic tool used is
made from a glass nozzle (0.025–0.50 mm diameter), which is smaller than the required
diameter. The ES process differs from STEM, which uses a coated titanium tube as a cathodic
tool.
To conduct the machining current i.e 25 A through the acid electrolyte that fills
the interelectrode gap, a platinum wire electrode is fitted inside the glass nozzle. Solutions of
sulfuric, nitric, or hydrochloric acid with a concentration of 12 to 20 wt % are common
electrolytes used. The type electrolyte used depends on the condition of the workpiece. In this
Regard, hydrochloric solution is used for aluminum and its related alloys, while sulfuric acid
solution is recommended for Hastelloy, Inconel, Rene alloys, and carbon and stainless steels.
The electrolyte temperature is normally 40°C for sulfuric acid and 20°C for the
rest. Electrolyte pressures between 275 and 400 kPa are recommended. During machining, the
electrolyte stream is negatively charged and squirted against the anodic workpiece. The acid
temperature, pressure, concentration, and flow rate must be carefully monitored for satisfactory
machining. A gap voltage of 70 to 150 V is employed, which is 10 times greater than that of
normal ECM.

Fig: Electrostream Drilling

PROCESS PARAMETERS & CAPABILITIES: Feed rates for ES drilling range from 0.75 to
2.5 mm/min. The feed rate depends on the material to be machined irrespective of the number of
holes to be drilled simultaneously. Similar to ECM, higher removal rates are associated with
larger feed rates and tool diameters. Additionally, higher removal rates have been reported for
titanium alloys than for steel. Normal tolerances are within ±10 percent of the produced hole
diameter. The normal hole depth tolerance is ±0.05 mm. These tolerance levels can further be
reduced using special control and with pure metals.

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 Electrolyte Temp: 40° C for sulphuric acid & rest 20°C for Nitric & hydrocloric acid
Electrolyte presure: 275 to 400 Kpa.
Voltage: A gap voltage of 70 to 150 V is employed, which is 10 times greater than that of
normal ECM.
Machining Current: 25 A
Normal Hole size & Depths: 0.15mm in dia to a depth of 6mm
0.25mm in dia to a depth of 12mm

APPLICATIONS:
 Drilling small rows of cooling holes in gas turbine blades & vanes
 Drilling WEDM Start holes less than 0.5mm
 Any application where high strength materials have to be substituted to improve quality,
performance, reliability & weight where machining is a problem

ADVANTAGES
 High depth-to-diameter ratios are possible.
 Many holes can be drilled simultaneously.
 Blind and intersecting holes can be machined.
 There is an absence of recast and metallurgical defects.
 Powder metallurgy hard materials can be tackled.
 Burr-free holes are produced.

LIMITATIONS:
 Can only be used with corrosion-resistant metals.
 Hazardous waste is generated.
 The process is slow when drilling a single hole.
 The handling of acid requires a special environment and precautions.

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