4M Knowledge base - papers

A H. J. Jeon (1), J Low (1), A. R. Mileham (1), A.N. Bramley (1), C. Johal (2)
1 Department of Mechanical Engineering, University of Bath, BA27AY, UK
2 Glacier Vandervell Bearings Ltd, Rugby, UK

Abstract

This paper describes the development, comparison and validation of a 3-D model of the electroplating process. It is based on the current density distribution that is generated using the Finite Element Method (FEM) and is used together with Faraday's law of electrolysis and various material and electrolyte values to determine the local plating depth. It has been developed initially to model the depth of the micro layer deposited on the work surface of an automotive engine’s "big end" shell bearing. Actual plating trials were conducted in a series of controlled laboratory experiments using an industrial type jig and industrial plating conditions. These consisted of a steel cathode (the bearing) and a lead anode. The results described here, in this paper, show good agreement between the 3-D simulation and the actual plating depth and profile and are considered to validate the model sufficiently for it to be used for electroplating tooling design and micro-electroforming.

J. Prokop (a),(b), J. Lorenz (a), V. Piotter (a), H.-J. Ritzhaupt-Kleissl (a), A. Roch (a), and J. Haußelt (a),(b)

(a) Forschungszentrum Karlsruhe GmbH, Institute for Materials Research III (IMF III) Hermann-von-Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, Germany
(b) Department of Microsystems Engineering - IMTEK, University of Freiburg, Germany

Abstract

A process for the fabrication of metal micro components by combining 2-component injection moulding with metal deposition by electroforming will be presented. To produce these 2-component polymer templates, an electrically conductive base plate is generated by injection moulding of electrically conductive carbon black-filled polymers. In a second injection moulding step microstructures consisting of insulating polymers are mounted onto these plates. The quasi-infinite conductivity gradient of such 2-component templates allows controlled electroplating to start from the base plate only, such that defect-free metal micro components can be achieved. The parameter set of the injection moulding process has been investigated by using an experimental method with an x-ray pattern analysis. Nearly defect-free electroplated micro parts could be fabricated by this process so far.