Emerging trends in hybrid ECM: a review of multi-assisted machining techniques

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Abstract Hybrid Electrochemical Machining (ECM) techniques have emerged as a promising solution for precision machining, particularly for hard-to-machine materials in industries like aerospace, biomedical, and micro-manufacturing. By integrating additional energy sources such as ultrasonic vibrations, magnetic fields, lasers, and plasma with conventional ECM, these hybrid processes overcome limitations such as low material removal rates, poor surface quality, and tool wear. This review provides a comprehensive overview of various hybrid ECM techniques, discussing their advantages, challenges, and current industrial applications. Key challenges highlighted include the high cost of equipment, complex process control, and difficulties in scaling up for large-scale industrial use. Recent advancements in smart monitoring systems and real-time feedback mechanisms offer potential solutions to these challenges by improving control over process parameters like electrolyte flow, voltage, and current density. The review also proposes hybrid-hybrid ECM—the integration of multiple assistive technologies—as a future research direction that could further enhance machining flexibility, precision, and surface quality. Additionally, the importance of sustainability in ECM processes, through the exploration of less hazardous electrolytes and energy-efficient techniques, is emphasized as a critical area for future research. Overall, this paper aims to guide future studies in advancing hybrid ECM technologies for broader industrial application and improved efficiency.