Fused deposition process combining electrochemical discharge with high speed selective jet electrodeposition

Abstract

Experiments have shown that the presence of a localised laser heat source significantly increases the deposition rate and deposit quality obtained by high speed selective jet electrodeposition (HSSJE). In this study, a relatively new process, fused deposition through electrochemical discharge (FDED), which uses heat generated by an aqueous electrochemical discharge in HSSJE, has been reported. The objectives of this investigation have been to identify the deposition mechanism and to compare FDED and laser-enhanced HSSJE with respect to deposition rate. During FDED, the nature of the deposited layer evolves with time, starting from a rough/dendritic layer to a powdery deposit at the top. Electrochemical discharge, depending on the voltage and standoff distance (SOD), can either fuse or erode the deposit. Experiments suggest that the metal deposition rate of 11 μg s−1 in FDED is of the same order as laser-enhanced HSSJE. The desired objectives of a smooth, fully compact deposit and high deposition rates can be obtained by an optimum combination of electrolyte flowrate, electrode SOD, applied voltage and table speed.