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Study of Localized Electrochemical Deposition for Metal Additive Manufacturing

Balsamy Kamaraj, Abishek
http://rave.ohiolink.edu/etdc/view?acc_num=ucin1539078938687749

Abstract Details

2018, PhD, University of Cincinnati, Arts and Sciences: Applied Economics.
In this study, the concept of localized electrochemical deposition of metals is combined with additive manufacturing principles, to achieve Electrochemical Additive Manufacturing (ECAM) – a novel non-thermal metal additive manufacturing process. The study focused on exploring the feasibility, understanding the process mechanism, and investigating the part quality of the ECAM process using experiments, simulations, and physics-based predictive modeling. The feasibility of the ECAM process was established in this research work by building in-house, an electrochemical deposition system that prints 3-D parts based on the input instructions received in the STL file format. Free hanging nickel parts with micron-scale resolution were printed using this system without the need for support structures. The mechanism of deposition of cations on to the substrate under varying process conditions was studied using finite element method based multi-physics simulations. The diffusion limited deposition process was simulated and found to agree with the experimental findings. The interelectrode gap (IEG) was found to be influential in the deposition rate and part quality. Three physics-based mathematical models were created in this study to predict the current density, rate of deposition, and deposit layer height respectively. An electrochemical first principles based model was developed to predict the diffusion layer characteristics and the current density variations during the process. This model was used to investigate the influence of electrolyte concentration, voltage, pulse frequency, and interelectrode-gap on the deposition current density. The model predicted that pulsed voltage with a lower duty cycle produces the highest peak current densities. The rate of deposition was modeled using the principles of Faraday's law and considering the geometry of the deposit. The rate of deposition was predicted by the model to be highest when using pulsed power with 75 % duty cycle. The layer height is an important parameter in additive manufacturing processes which determines the resolution and quality of the parts manufactured. The developed layer height prediction model takes the electrical process parameters and the scan speed as inputs and gives the deposited layer height as the output. The model predicted that there exists a lower limit for the scan speed for each IEG, below which a possibility of short-circuiting exists. The additive manufactured part quality and porosity were found to be controllable by varying the pulse power and interelectrode gap parameters. Two types of pores were identified in the electrodeposited nickel parts. The pore size distribution study of the parts shows the scale of the micro pores formed during this process to be less than 10 µm.
Murali Sundaram, Ph.D. (Committee Chair)
Sam Anand, Ph.D. (Committee Member)
Jing Shi, Ph.D. (Committee Member)
Vijay Vasuedevan, Ph.D. (Committee Member)
126 p.
Mechanical Engineering
Electrochemical Deposition; Additive Manufacturing; Theoretical Model; Multiphysics Simulation; Porosity; Nickel

Recommended Citations

Citations

  • Balsamy Kamaraj, A. (2018). Study of Localized Electrochemical Deposition for Metal Additive Manufacturing [Doctoral dissertation, University of Cincinnati]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1539078938687749

    APA Style (7th edition)

  • Balsamy Kamaraj, Abishek. Study of Localized Electrochemical Deposition for Metal Additive Manufacturing. 2018. University of Cincinnati, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=ucin1539078938687749.

    MLA Style (8th edition)

  • Balsamy Kamaraj, Abishek. "Study of Localized Electrochemical Deposition for Metal Additive Manufacturing." Doctoral dissertation, University of Cincinnati, 2018. http://rave.ohiolink.edu/etdc/view?acc_num=ucin1539078938687749

    Chicago Manual of Style (17th edition)

ucin1539078938687749
519
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This open access ETD is published by University of Cincinnati and OhioLINK.