Creating Complex Hollow Metal Geometries Using Additive Manufacturing and Metal Plating

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dc.contributor.authorMcCarthy, David Leeen
dc.contributor.committeechairWilliams, Christopher B.en
dc.contributor.committeememberHuxtable, Scott T.en
dc.contributor.committeememberTarazaga, Pablo Albertoen
dc.contributor.departmentMechanical Engineeringen
dc.date.accessioned2014-03-14T21:39:30Zen
dc.date.adate2012-07-23en
dc.date.available2014-03-14T21:39:30Zen
dc.date.issued2012-06-25en
dc.date.rdate2012-07-23en
dc.date.sdate2012-07-05en
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
dc.description.degreeMaster of Scienceen
dc.identifier.otheretd-07052012-121837en
dc.identifier.sourceurlhttp://scholar.lib.vt.edu/theses/available/etd-07052012-121837/en
dc.identifier.urihttp://hdl.handle.net/10919/43530en
dc.language.isoenen
dc.publisherVirginia Techen
dc.relation.haspartMcCarthy_DL_T_2012.pdfen
dc.relation.haspartMcCarthy_DL_T_2012_Copyright.pdfen
dc.rightsIn Copyrighten
dc.rights.urihttp://rightsstatements.org/vocab/InC/1.0/en
dc.subjectElectroless Platingen
dc.subjectAdditive manufacturingen
dc.subjectElectroplatingen
dc.subjectSelective Laser Sinteringen
dc.subjectElectroformingen
dc.titleCreating Complex Hollow Metal Geometries Using Additive Manufacturing and Metal Platingen
dc.typeThesisen
thesis.degree.disciplineMechanical Engineeringen
thesis.degree.grantorVirginia Polytechnic Institute and State Universityen
thesis.degree.levelmastersen
thesis.degree.nameMaster of Scienceen

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