Research Article Open Access

Lab Scale Process Optimization for Manufacturing of Thin-Walled Hollow Shapes of Nickel by Electrodeposition

Abstract

Electroforming is an extension of electrodeposition process wherein one metal is deposited onto a cathode in the shape of a required geometry called a ‘mandrel’. After deposition the mandrel is removed by preferential dissolution leaving behind a hollow thin-walled structure of the deposited metal. Electroforming is considered a strong contender for fabrication of lightweight, thin walled (few microns) components with high dimensional accuracy, intricate shape, precise reproduction of surface details with miniature geometry. This research was aimed to produce thin-walled complex shaped nickel components and to investigate the effect of process parameters including electrolytic solution composition, on surface morphology and mechanical properties of the product. Careful control of ingredients along with processing parameters resulted in wall thickness from 40 to 130 microns with tensile strength varying between 400 to 1100 MPa with a maximum hardness up to 750 Hv.

Muhammad Shahid*, Usama Bin Aslam, Malik Adeel Umer, Muzammil Hussain, Muhammad Faisal Rathore, Fahd Nawaz Khan

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