Research Progress of Electrochemical Machining Technology in Surface Processing: A Review.

Traditional mechanical processing techniques are confronted with significant challenges when machining advanced materials possessing excellent mechanical properties. Electrochemical machining (ECM), as a material removal technology based on the principle of anodic dissolution, demonstrates distinctive advantages including the absence of contact stress, independence from material hardness, and elimination of mechanical residual stress and recast layers. These characteristics render ECM particularly suitable for high-precision applications requiring superior surface quality. This review systematically summarizes the applications, recent progress, and current challenges of ECM in surface processing. According to diverse surface requirements, ECM technology is classified into two core directions based on primary objectives. The first direction focuses on surface quality enhancement, where nanoscale planarization, residual stress reduction, and uniform surface performance are achieved through precise regulation of anodic dissolution. The second direction concerns material shaping, which is subdivided into macro-scale and micro-scale processing. Macro-scale forming combines electrochemical dissolution with mechanical action to maintain high material removal rate (MRR) while achieving micron-level precision. Micro-scale forming employs nanosecond pulse power supplies and precision electrode/mask designs to overcome manufacturing limitations of micro-nano features on hard-brittle materials. Despite progress achieved, key technical bottlenecks persist, including unstable dynamic control of the inter-electrode gap, environmental concerns regarding electrolytes, and tooling degradation. Future research should prioritize the development of green processing technologies, intelligent control systems, multi-scale manufacturing strategies, and multi-energy field hybrid technologies to enhance the capability of ECM in meeting increasingly stringent surface requirements for advanced materials.