Magnetic field-assisted electrochemical additive manufacturing of nickel structure: Growth mechanism and microstructural evolution

Abstract

The microstructure and crystal texture of magnetically assisted electrochemical additive manufacturing parts play crucial roles in their mechanical properties and applications. This paper elucidates the electrocrystallization process of electrochemical additive manufacturing by constructing a magnetically assisted setup and exploring both nucleation mechanisms and growth kinetics. The electrochemical behavior of the system was analyzed using electrochemical methods under different magnetic field strengths. Nickel structures with aspect ratios of 7.0 and 8.2 were fabricated using the experimental setup, and their morphology, crystal texture, and microstructure were characterized. The results showed that without applying a magnetic field, the nucleation mechanism followed three-dimensional instantaneous nucleation under diffusion control. Under magnetic field conditions, forced convection, double layer charging, and hydrogen evolution reactions were combined to modify the S-H nucleation model, demonstrating that the magnetic field can significantly enhance the nucleation rate and number of nuclei. The initial growth of the microstructure did not exhibit preferential solid orientation, primarily forming refined equiaxed grains. Subsequently, a characteristic pentagonal structure developed, followed by spiral dislocation growth, with a significant transformation of equiaxed grains into columnar crystals. The crystal orientation eventually evolved to <110>, with many twin boundaries, among which Σ3 grain boundaries accounted for more than 55 %. Applying a magnetic field improved processing efficiency, altered the morphology and texture of the material, refined the grains, and increased the types of twins. These results provide theoretical and experimental support for electrochemical additive manufacturing.