Weld Removal and Exhaust Manifolds

This application uses PECM to smooth and finish complex internal passages, such as those found in exhaust manifolds and other cast or welded components.

Materials Machined

• Stainless steel
• High-strength steel
• Cast iron

Market Sectors

• Automotive: Exhaust headers and manifolds, intake ports.
• Formula 1: High-performance engine components.
• Marine: Exhaust systems and manifolds for marine engines.

Key Benefits & Numbers

• Improved Performance: Improves gas and fluid flow by up to 20% by removing internal weld beads and smoothing the inner surface.
• Rapid Processing: Removes weld beads in a process that takes less than 10 minutes per manifold, which would be extremely labor-intensive to achieve manually.
• Unmatched Consistency: Provides a highly repeatable process that ensures every part has a uniform internal surface finish, critical for consistent performance.

Relevant Industry Standards

• ASTM F1600: Standard Test Method for Determining the Flow Characteristics of Manifolds.
• SAE J1930: Diagnostic Trouble Code Definitions for Automotive Systems. (While not directly about manufacturing, a smooth internal surface reduces flow restrictions that can lead to diagnostic codes).
• ISO 8178: Reciprocating internal combustion engines — Exhaust emission measurement.

Academic References

• Micro electrochemical machining for complex internal micro features
• Diverless weld inspection and repair using ECM/ACFM techniques