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Fabrication of high-thickness and low surface roughness metal parts by a hybrid electrochemical manufacturing process

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Fallah, Panteha, Hof, Lucas A. et Wuthrich, Rolf. 2021. « Fabrication of high-thickness and low surface roughness metal parts by a hybrid electrochemical manufacturing process ». Advances in Industrial and Manufacturing Engineering, vol. 2.

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Abstract

Electroforming on additively manufactured templates has the potential to become a manufacturing process for making complex metal parts in a flexible and economical way. However, the main challenge of electroforming is the high surface roughness when deposition thickness increases (thickness ​> ​100 ​μm), due to the high current density on edges and co-deposition of impurities while electroforming. In this work, a hybrid electrochemical manufacturing process to fabricate high-precision metal parts is proposed combining electroplating and surface levelling to achieve thick deposits (up to 1 ​mm) with a low surface roughness. The presented work includes a comparative study of electroforming technologies to fabricate precision metal parts on additively manufactured templates. The potential of this methodology was demonstrated by forming a copper layer on additively manufactured ABS (acrylonitrile butadiene styrene) models. The proposed hybrid electroforming method results in a simple process design, as no specific chemistry (e.g. lack of additives) is needed. Another benefit of this indirect additive manufacturing process is the reduction of the carbon footprint compared to direct printing by usage of metal salts instead of refined metals.

Item Type: Peer reviewed article published in a journal
Professor:
Professor
Hof, Lucas
Affiliation: Génie mécanique
Date Deposited: 25 Jan 2022 20:39
Last Modified: 03 Mar 2022 16:07
URI: https://espace2.etsmtl.ca/id/eprint/23880

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