Flow block sealing methods

A method for pulsed electrochemical machining (pECM) a workpiece, comprising:

• positioning a working surface of one or more electrodes relative to a target surface of a workpiece to remove material from the target surface of the workpiece;
• forming a seal surrounding at least a portion of a perimeter of an interelectrode gap, the at least one seal configured to reduce or eliminate flow of an electrolyte out of the portion of the perimeter of the interelectrode gap, the at least one seal formed by a first flow block coupled to a tool body and a second flow block coupled to the workpiece, wherein forming the seal comprises:
• positioning a cathode seal body surrounding a perimeter of the tool body, the cathode seal body preventing electrolyte from flowing along sides of the tool body adjacent to the first flow block, and wherein positioning the cathode seal body includes
• disposing the cathode seal body in a cathode seal collar defined by the first flow block, wherein the cathode seal body comprises a groove defined along at least a portion of the perimeter of the cathode seal body, the groove mechanically supporting a cathode seal body gasket, wherein the cathode seal body gasket forms a seal between the cathode seal body and the first flow block;
• delivering the electrolyte into the interelectrode gap between the working surface of the one or more electrodes and a target surface of the workpiece;
• and
• generating a pulsed direct current between one or more electrodes of a machining tool and the workpiece, wherein the machining tool comprises the tool body defining a tool axis, the tool body comprising the one or more electrodes, each of the one or more electrodes comprising an electrically conductive material and defining the working surface at a distal end of the tool axis configured to face the workpiece.