Thesis
Nickel electroforming for large-scale applications : process modelling & optimisation
- Creator
- Rights statement
- Awarding institution
- University of Strathclyde
- Date of award
- 2022
- Thesis identifier
- T16557
- Person Identifier (Local)
- 201990980
- Qualification Level
- Qualification Name
- Department, School or Faculty
- Abstract
- Electrochemical forming is a chemical additive process to manufacture a variety of niche components. Its capability has been exploited in micro-manufacturing as well as “heavy industry”, such as aerospace. As the “Industry 4.0” era unfolds, there is a need to develop models for electroforming which are based on electrochemically sound data. To do this, physical and electrochemical parameters for modelling purposes should be determined first, followed by rigorous modelling studies. For modelling to be useful, parameters which could play a significant role in process optimisation should be examined, followed by continuous cross-validation through appropriate measurements. Through that way a model can be a valuable aid, allowing predictability in tooling, piloting, and manufacturing in a reliable manner. In that context, during this project the effect of physical and electrochemical parameters on electroformed parts was studied and a well-informed modelling tool, using COMSOL Multiphysics®, was developed. The model was subsequently validated through carefully designed experiments. That way, this project succeeded in bridging the gaps among electrochemistry, chemical engineering, and manufacturing. Specifically, to meet the industrial partner’s (Radius Aerospace Bramah) vision for large scale and large-volume manufacturing of large parts with extremely high precision, the key engineering variables which can be used to manipulate an electroformed part were identified and a 5-step systematic approach of studying the electroforming process was established. The industrial partner was provided with a well-informed and validated model of the process, as well as suggestions towards the optimisation of the electroforming reactor and auxiliary tooling (e.g., “masks” and thieves”). Upon implementation, the proposed 5 step methodology could allow for process scaling-up and volume manufacturing while minimising the number of manufacturing trials and process waste.
- Advisor / supervisor
- Roy, Sudipta
- Resource Type
- DOI
Relations
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