Fabrication of a Tool Electrode with Hydrophobic Features and Its Stray-Corrosion Suppression Performance for Micro-electrochemical Machining.
Langmuir
; 38(8): 2711-2719, 2022 Mar 01.
Article
en En
| MEDLINE
| ID: mdl-35156825
ABSTRACT
Micro-electrochemical machining (micro-ECM) can machine microstructures with excellent surface integrity on difficult-to-cut alloys. During micro-ECM, stray corrosion results in tapered sidewalls of machined structures. To suppress the stray corrosion, a novel tool electrode with the sidewall insulation of a gas film is proposed by fabricating the metal tool sidewall into a hydrophobic surface. The sidewall surface is designed to be characterized with spherical array cavities (radius of 500 nm) acting as the hydrophobic features, enhancing the gas-shielding effect of the gas film under electrolysis. The fabrication process of the hydrophobic sidewall is described in detail, including the self-assembly procedure of a monolayer template of Φ1 µm polystyrene microspheres, the copper-electroforming procedure for filling the microspheres' gaps, and the removal procedure for forming spherical array cavities. The fabricated tool electrode (Φ500 µm) obtains the hydrophobic features of a contact angle of up to 138°. As a result, bubbles generated on the tool surface can form an air-electrolyte interface instead of a dispersed bubble cluster. Micro-ECM experiments of microstructures verify that the novel tool electrode can improve machining accuracy by suppressing sidewall stray corrosion.
Texto completo:
1
Banco de datos:
MEDLINE
Idioma:
En
Revista:
Langmuir
Asunto de la revista:
QUIMICA
Año:
2022
Tipo del documento:
Article
País de afiliación:
China