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dc.contributor.authorMcCarthy, David Leeen_US
dc.date.accessioned2014-03-14T21:39:30Z
dc.date.available2014-03-14T21:39:30Z
dc.date.issued2012-06-25en_US
dc.identifier.otheretd-07052012-121837en_US
dc.identifier.urihttp://hdl.handle.net/10919/43530
dc.description.abstractAdditive manufacturing introduces a new design paradigm that allows the fabrication of geometrically complex parts that cannot be produced by traditional manufacturing and assembly methods. Using a cellular heat exchanger as a motivational example, this thesis investigates the creation of a hybrid manufacturing approach that combines selective laser sintering with an electroforming process to produce complex, hollow, metal geometries. The developed process uses electroless nickel plating on laser sintered parts that then undergo a flash burnout procedure to remove the polymer, leaving a complex, hollow, metal part. The resulting geometries cannot be produced directly with other additive manufacturing systems. Copper electroplating and electroless nickel plating are investigated as metal coating methods. Several parametric parts are tested while developing a manufacturing process. Copper electroplating is determined to be too dependent on the geometry of the part, with large changes in plate thickness between the exterior and interior of the tested parts. Even in relatively basic cellular structures, electroplating does not plate the interior of the part. Two phases of electroless nickel plating combined with a flash burnout procedure produce the desired geometry. The tested part has a density of 3.16g/cm3 and withstands pressures up to 25MPa. The cellular part produced has a nickel plate thickness of 800µm and consists of 35% nickel and 65% air (empty space). Detailed procedures are included for the electroplating and electroless plating processes developed.en_US
dc.publisherVirginia Techen_US
dc.relation.haspartMcCarthy_DL_T_2012.pdfen_US
dc.relation.haspartMcCarthy_DL_T_2012_Copyright.pdfen_US
dc.rightsI hereby certify that, if appropriate, I have obtained and attached hereto a written permission statement from the owner(s) of each third party copyrighted matter to be included in my thesis, dissertation, or project report, allowing distribution as specified below. I certify that the version I submitted is the same as that approved by my advisory committee. I hereby grant to Virginia Tech or its agents the non-exclusive license to archive and make accessible, under the conditions specified below, my thesis, dissertation, or project report in whole or in part in all forms of media, now or hereafter known. I retain all other ownership rights to the copyright of the thesis, dissertation or project report. I also retain the right to use in future works (such as articles or books) all or part of this thesis, dissertation, or project report.en_US
dc.subjectElectroless Platingen_US
dc.subjectAdditive Manufacturingen_US
dc.subjectElectroplatingen_US
dc.subjectSelective Laser Sinteringen_US
dc.subjectElectroformingen_US
dc.titleCreating Complex Hollow Metal Geometries Using Additive Manufacturing and Metal Platingen_US
dc.typeThesisen_US
dc.contributor.departmentMechanical Engineeringen_US
dc.description.degreeMaster of Scienceen_US
thesis.degree.nameMaster of Scienceen_US
thesis.degree.levelmastersen_US
thesis.degree.grantorVirginia Polytechnic Institute and State Universityen_US
thesis.degree.disciplineMechanical Engineeringen_US
dc.contributor.committeechairWilliams, Christopher Bryanten_US
dc.contributor.committeememberHuxtable, Scott T.en_US
dc.contributor.committeememberTarazaga, Pablo A.en_US
dc.identifier.sourceurlhttp://scholar.lib.vt.edu/theses/available/etd-07052012-121837/en_US
dc.date.sdate2012-07-05en_US
dc.date.rdate2012-07-23
dc.date.adate2012-07-23en_US


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