Electroforming and electrodeposition on complex 3d geometries: Special requirements and new methods

Abstract

The chapter presents fields of electrodeposition where nanostructuring of nickel is challenging (electroforming, replication of fine-structured surfaces, filling of small-and large-scaled notches, e.g., in microsystem technology and for electroformed slush-tools for automotive of dashboards for automotive applications). It outlines the special requirements for the electroforming process of thick complex 3D-shaped deposits including bath analytics and stress measurements which are essential for the production of thick deposits, where the properties are hardly affected by impurities and internal stresses. Methods for the filling of the notches are presented. We further describe a new electrodeposition method to produce continuous fiber-reinforced metal matrix composites. Incorporating the fibers modifies the electrocrystallization and produces nanocrystalline structures around the fibers. As a hot special topic a new electrodeposition method is described to coat 3D porous structures as metal foams that there is an almost homogeneous coating thickness over the total cross section of the foams. The special experimental setup, special mass transport, and deposition mechanism in order to produce nanocrystalline nickel coatings around the foam struts are explained.