Material Removal by Arc Ablation

Arc ablation holds the promise of fast, low-cost metal removal at faster rates than laser, plasma and electron-beam methods and without the tooling and fixturing forces of conventional machining. Preliminary results show surface finishes in the tens of microns range at high material removal rates (MRRs) by adaptive control of arc voltage: up to 97 mm3/sec at 4 kW. These results far exceed the capabilities of Plasma cutting for the same power ranges. Arc ablation can remove hardened die steels at controlled depths without dielectric baths, shield gasses or tool wear. We have also successfully cut Inconel 718 and Titanium 64. Benefit-to-risk ratios are moderate since we do not need substantially new machines for this new process. Conventional lathes and mills can be employed through insulated tooling configurations. The immediate challenges are the extension of surface ablation to hole-making and ten times the preliminary MRR: up to 1000 mm3/sec at 40 kW.