Local surface nanoscale modification by Jet Plasma electrolytic Polishing

Surface processing has become indispensable for numerous high-tech industries. The so-called plasma electrolytic polishing is an environmentally friendly technology. The component surface can be smoothly processed with superimposed electrical and chemical mechanisms of action. Complex components can be machined quickly, efficiently and with consistent quality using this process. In medical technology implants, for example, by applying suitable surfaces it is possible that the body tissue grows well with the implant with no undesired bacterial growth. This presents a great challenge due to the extremely complicated shaped components as well as the different surface properties and the desired accuracy. The aim of the Jet-PeP research project was therefore to make plasma polishing selectively usable on component surfaces. The focus was on the innovative plant technology for localized application and spatial guidance of the plasma with a special high-performance energy source. First of all, local processing was developed using a jet-based process in order to generate the required plasma only at the desired locations. By measuring and analyzing chemical and electrical parameters on the resulting system, knowledge about the effect and expansion of the plasma on the components was elaborated. These were of crucial importance for the development of the process and precondition for the transfer of the technology into industrial application. The investigations were supported by so-called multiphysical simulation methods, to calculate partial phenomena like film boiling behavior in order to support the development of different system components. The components developed and the knowledge obtained were converted into prototypical applications. This enabled the selective machining of surfaces of complicated components by the plasma electrolytic process. New design options are enabled and energy savings of up to 30 percent can be achieved due to the possibility of the targeted selection of machining areas and the optimized component design. In addition to medical technology, the jet-based plasma electrolytic polishing has been further developed for applications in the automotive industry or aerospace technology. The German-Israeli consortium united the excellence of mechanical engineering, electrical engineering, materials science and precision manufacturing.

The German partners in this joint project with Israeli partners were funded by the "Innovations for the Production, Services and Work of Tomorrow" program of the Federal Ministry of Education and Research (BMBF). We would like to take this opportunity to thank everyone who has contributed to this pioneering research and development work with their knowledge, commitment and experience.

Project Management Agency Karlsruhe (PTKA)
Production, Service and Work
Karlsruhe Institute of Technology (KIT)

Stefan Scherr March 2021