Session: 02-04-01: Session #1: Advanced Machining and Finishing Processes

Paper Number: 96200

96200 - Application of Nickel Deposition on Electropolishing (EP), Chempolishing (CP), and As-Built Additively Manufactured (AM) Metal Components 

APPLICATION OF NICKEL DEPOSITION ON ELECTROPOLISHING (EP), CHEMPOLISHING (CP), AND AS-BUILT ADDITIVELY MANUFACTURED METAL COMPONENTS

Pablo E. Sanchez Guerrero,  Zafar Waqar, Pawan Tyagi

Center for Nanotechnology Research and Education, Mechanical Engineering, University of the District of Columbia, Washington DC-20008, USA

 

Existing additive manufacturing (AM) technologies produce metal components with a rough surface that generally display fatigue characteristics, leading to component failure and undesirable friction coefficients to the printed part. Small cracks formed at regions of high surface roughness in rough surfaces, act as a stress raiser or crack nucleation site. Hence, as-produced parts' direct use is limited and introduces a challenge related to smoothening the surface. The present study explores the application of electroless nickel deposition and examines the surface finishing techniques such as ChemPolishing (CP) and ElectroPolishing (EP) for postprocessing on additively manufactured stainless-steel samples. Previous studies have demonstrated that CP has a great advantage in creating uniform, smooth surfaces regardless of size or part geometry. EP Electropolishing has excellent surface finishing capability with high material removal rate. However, electropolishing has some limitations with uniformity and repeatability. Electroless nickel deposition has superior plating potential on additively manufactures stainless samples. Nickel offers excellent wear resistance and nickel-plated samples up to two times scratch resistant through the scratch testing process than as produced samples. The high phosphorus electroless nickel solution gives extra corrosion resistance. Using electroless nickel solutions, the study also investigates nickel deposition on EP, CP, and as-built AM components. Electroless nickel plating is a chemical process that deposits an even layer of nickel-phosphorus alloy on the surface of the substrate. It is a treatment designed to increase manufactured components' hardness and surface resistance to the implacable environment. The electroless nickel plating process is simpler than its comparable electroplating. In this study, we use medium-phosphorus (6-9% P), and high-phosphorus (10- 13% P). The Ni deposition experiments were optimized using the L9 Taguchi design of experiments (DOE), which involve the prosperous content in the solution, surface preparation, plane orientation of the sample geometry, and Nickel strike exposition time. The pre-and post-processed surface of the AM parts is being investigated by the KEYENCE Digital MicroscopeVHX-7000 and Phenom XL Desktop SEM. The experimental results measurements are in process, and the mechanical properties of as-built and Ni coated additive  manufacturing (AM) samples are being examined by applying a standard 5 N scratch test.

Keywords: additive manufacturing, chempolishing, electropolish, plating, hardness, Taguchi design of experiments, crack nucleation, surface finish.

 

Presenting Author: Pablo Sanchez University of the District of Columbia

Presenting Author Biography: I am a multidisciplinary professional in Civil Engineering and in Industrial Engineering. I have a Master’s degree in Civil Engineering and a Master’s degree in Water Resources Management. I earned my first engineering degree in Industrial Engineering from the University National Experimental del T&#225;chira, San Crist&#243;bal, T&#225;chira State, Venezuela, in 1987. Afterward, I have worked as an Industrial Engineer for more than twenty years in production, maintenance, operation standardization, planning and control of projects, and a number of related disciplines in the food, plastic, hydroelectric power, automotive, construction, and agriculture industries. I have gained extensive experience in traditional manufacturing methods, including primary manufacturing processes: casting (injection-molding), forming (forging, rolling, extrusion), joining (welding, soldering, fastening, epoxying), and secondary manufacturing processes: machining (turning machines and boring mills), shapers and planers, drilling machines, milling machines, grinding machines, power saws, presses and surface working, such as heat treatments and thin coatings.<br/>I moved to the United States in 2009. I graduated in Civil Engineering from the University of the District of Columbia, Washington DC, U.S.A. in 2014. I worked as an intern in D.C. Water during the summers of 2013 and 2014. Following my internship, I worked as a Field Engineer for Whiting-Turner Contracting Company &amp; Gilford Corporation for the M.G.M National Harbor Grand Casino Project, which was more than a 1 Billion Dollar project at the Prince George County, Maryland. <br/>Since November 01, 2015, I am working as a Laboratory Engineer at the School of Engineering and Applied Sciences of the University of the District of Columbia, Washington DC. I graduated in the Professional Science Master in Water Resources Management in Fall 2018 and a Master of Science in Civil Engineering in Spring 2021. As a Laboratory Engineer, I have worked in the EOSINT M280 Metal 3D Printer Site Preparation, Installation, and start-up jointly with the E.O.S. field Engineer. I currently assist students in operation and maintenance of the printer. Likewise, I have been supporting faculty and students in the COVID-19 face shield rapid prototype production for a community project/donation to D.C. Government (3D plastic printing), SEAS Senior Capstone Projects in the machine shop, executing the restoration and start-up of the C.N.C. (Computer Numerical Control) Milling Machine GANESH GBM-2616, and teaching laboratory classes of Geotechnical Engineering, Concrete, Hydrology and Hydraulics, ThermoFluid, Solid Mechanics, and Structure. I have been working diligently in:<br/>1. Special Competitions such as Student Steel Bridge Competition during 2016 (first-time U.D.C. historical participation in the competition), 2017, 2018 (U.D.C. historical accomplishment in the competition getting Second (2nd) Place in the Virginia Conference), and 2019.<br/>2. N.A.S.A. Human Exploration Rover Challenge 2018 (2nd place among the all-rookie teams, and the 7th place overall out of 100 national and international University teams), 2019, and 2020.<br/>3. The Revolutionary Aerospace System Concepts Academic linkage RASC-AL Special Edition Challenge 2019. <br/>4. Assembling and starting up Rethink Robotics Sawyer, a high-performance collaborative robot for Mechatronics Laboratory.<br/>5. Setting up Ambulatory Suspension System (Navigator) and Vicon Motion Capture System for Bio-Engineering and Bio-Medical Research Laboratory.<br/>6. The Establishment of new equipment for Renewable Energy Laboratory known as Smart Grid Solar and Wind Power Generation Trainer Apparatus (WE 210), including the experimentation on Electrolysis of Hydrogen and Oxygen (hydrogen energy cells), Solar energy (photovoltaic cells), Wind energy modulus, and intelligent grid.<br/><br/>My research interests are computer science and engineering, including Advanced Manufacturing, Nanofabrication, and Biomedical engineering tied to human mobility and prosthetics. What motivates my research interests is the quality of life improving capability of these disciplines and my deep desire and passion for becoming an advanced-level multidisciplinary expert in these disciplines. As an experienced Industrial Engineer, I would like to explore and get expertise in Advanced Manufacturing processes and Nanotechnology-Nanofabrication. These disciplines incorporate innovative technologies to improve products and processes and have a wide range of applications in other disciplines such as Civil Engineering, Industrial Engineering, and Biomedical Engineering. The opportunity to investigate 3D Medical Applications of prosthetics for veterans with blast injuries or amputees excites encourages me to serve our veteran heroes. <br/>I strongly believe in work ethics, technical skills, integrity, honesty, sincerity, discipline, methodology, teamwork, hard work, and determination to achieve all the required objectives. I possess excellent interpersonal skills to establish and maintain positive working relationships. I am a quick learner and flexible to adapt to any new technical scenario.

Authors:

Pablo Sanchez University of the District of Columbia
Zafar Waqar University of the District of Columbia
Pawan Tyagi University of the District of Columbia