TakingtheStressoutofElectroforming

Electroformingof
LightWeight
EngineeringComponents
B.Stein,MIMF,NiCoForm,Inc.

Copyright2009NiCoForm,Inc.,Rochester,NYUSA

TalkOverview

WhatisElectroforming?
HowElectroformingWorks(bellowsexample)
AdvantagesofElectroforming
Electroforms:ExamplesandUniqueBenefits:

BellowsandBellowsAssemblies
Complex3DShapes(airducts)
SpaceflightandRadiationShields

Summary

WhatisElectroforming?

Afabrication
techniqueinwhicha
layerofmetalis
electroplated(formed)
ontoamandrel
(originalormodel),
andthenseparated
fromit,resultingina
selfsupporting,
seamless,nearnet
shapepart

HowelectroformingworksBellows
Example
1. Mandrelismachinedandinspected
2. NiColoyiselectroplated(formed)ontothemandrel
3. Mandrelischemicallyremoved
4. Flangesareattachedbyelectrojoining
3

PropertiesofNiColoy

HighYieldStrength130kpsi,UTS160kpsi

HighYoungsModulus14Mpsi

Hardnessrange3055RockwellC

Porefreedepositleaktightto109 ccHe/sec

Wallthicknessrangingfrom12.5m/.0005to>6
mm/0.25

Highcorrosionresistance

Isotropicthroughoutthematerialthickness

Customizableperapplicationrequirements

Minimalinternalstresses

BellowsApplications

Pressureorvolumeaccumulators
Scrollpumphousings
Valvestemseals
Flexiblecouplings
Sensors
Switches

BellowsAssemblies

Electroformedbellows(right)and
bellowselectrojoinedtoInconel
components(left)

200mm(8)ODbellowselectrojoinedto
stainlesssteelflanges

HighPressureDiaphragm

Electroformed 6 mm (0.25) OD
diaphragm, electrojoined to Inconel
components

Electroformingallowsto
producebellowsand
diaphragms<10mm
(0.5)indiameter,with
walls<10m(0.0005),
providingforhigh
sensitivityandlong
componentcyclelife.
Electrojoiningpreserves
thealloy'shigh
mechanicalstrengthafter
assembly

DistinctiveFeaturesofElectroformed
BellowsandDiaphragms

Lowerwallthicknessandgreatersensitivitythan
possiblebyothermethods
Smallersizethanpossiblebyothermethods
Isotropicalloyproperties,freedomfromheator
workinducedweaknesses
Freedomfromporosity
LowerCostforbatchesunderabout1,000
Nonroundcrosssections(square,rectangular)
andcurvedconfigurationsarepossible
Integratedflangesandotherelementscanbe
easilyincorporated

NetShapeElectroformedAirDuct

Featuresmade
possibleby
electroforming:
Stressfreecomplex
3Dshape

Singlepiecearticle

Countersinksand
mountingholes
producedinplace

LargeAirDuctMandrel(left)
andElectroform(right)

Tightdimensionaltolerances

Shortenedmanufacturingcycle

Eliminationofsecondaryops

Highstrengthalloy

LightWeightSinglePiecePart

Uniquefeaturesmadepossibleby
electroforming:

ColdShieldsandMiniatureHousing

UniqueFeaturesmade
possiblebyelectroforming:

Lightweight,thin
(.002/50m)wall
Dimensionaltolerances
<.0005/12.5m
Lightabsorbing/light
reflectivefinishesonthe
inner/outersurfaces
Texturedfinishonthe
innersurfaces

ESAPlanetaryBaffleMERTIS
(BepiColomboMissiontoMercury)

http://www.esa.int/science/bepicolombo

Uniquefeaturesmade
possibleby
electroforming:

Extremelylightweight0.232kg(~0.5lb)
0.2mm(0.008)Wallthickness
Tighttolerances+/.02mm(0.0008)
Opticalqualityinternalsurfaces
Highstiffness:firsteigenfrequency@296Hz
OperatingTemperatureupto200C(400F)

PhotocourtesyofInstitutefor
Planetology/Muenster,DLR/Berlin
andKayserThrede/Munich

AdvantagesofElectroforming

Lightweight,highstrength,tighttolerancecomponents
Thin,porefreeandstrainfreecrosssectionspossible
Singlepiecedesign
Highcorrosionresistance
Reducedsecondaryoperations
Fastturnarounds
Moderatecost
Selectionofmetals:NiColoy,Nickel,Copper
Selectionofjoiningmethods:electrojoining,soldering,
brazing,welding,adhesives

NetShapeElectroforms

Opticalmoldinserts(1&5)
Miniaturebellows(2)
Airscoopsorcustomductwork(3)
Microfluidicmoldinsert(4)

WhenisElectroforming
CostBeneficial?

Smallbatch(<1000units)productionandrapid
prototypingofcomplex3Dgeometrymetalparts
Lightweight,highstrengthcomponents
Thincrosssection3Delasticcomponents
bellows,membranes,diaphragms,MEMS
devices
Precisionmoldinsertsforopticalandmicrofluidic
components
SmallID,highsurfacefinish,tightlytoleranced
cavities,e.g.cathetertipformingdies,miniature
opticalhousings,etc.

TakingtheStressoutofElectroforming

www.nicoform.com
emailinform@nicoform.com
phone0015854545530
tollfree877NICOLOY
fax0015854545167
Contact us and Take the Stress Out of Your
Projects

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