Electroforming is an essential process in metal forming. Due to its high replication rate and dimensional accuracy, this process is widely used in industries such as aerospace, instrumentation, and precision parts. As an advanced technology, it has attracted widespread attention from the manufacturing industry both domestically and internationally.

 

What is the basis for electroforming? What are the principles of electroforming?

1. Principles of Electroforming: Electroforming and electroplating share similar principles, both utilizing an electrochemical process to achieve forming. Electroforming uses a cathode deposition phenomenon on a mold during the electrochemical process, causing metal to accumulate and separate, resulting in the production of metal products. However, electroforming differs from electroplating in that electroplating primarily bonds to the substrate to form a strong coating, achieving the desired protective or decorative effect. In electroforming, under the influence of a DC power source, metal ions in metal salts lose electrons and become metal ions. And continuously add it to the electroforming liquid to keep the concentration of the electroforming liquid basically constant. When the electroforming layer on the original mold reaches the required thickness, it is removed, the electroforming layer and the original mold are separated, and an electroforming part with the same shape as the original mold is obtained.

 

2. Characteristics of electroforming processing

(1) The precision of electroforming imitation is high, and it can imitate complex surfaces and delicate temperatures. The surface roughness of the imitation can reach 0.1 micron, and it can be used directly without polishing.

(2) The service life of the electroforming cavity is long, and its surface hardness can reach 35-50hrc.

(3) The processing process is simplified, one-step molding can be completed, and the amount of finishing required is very small.

(4) The metal products obtained by electroforming are of high purity. For example, electroformed copper is not only of high purity but also has good conductivity, which is conducive to electroforming.

(5) Electroforming processing also has disadvantages. During electroforming, the metal deposition speed is slow and the production cycle is long. When electroforming a 1mm thick product, a simple shape takes 3 to 4 hours, while a complex shape product may take dozens of hours. For example, electroforming nickel takes about a week to deposit.

 

3. Electroforming process

(1) Model making: The electroforming model is different from the cavity. When making the model, the material can be selected from aluminum, copper, low carbon steel and alloys with low melting points, etc.

(2) Surface treatment: Before electroforming, the original mold needs to be cleaned to remove dirt and oil to ensure that metal ions can adhere to the surface.

(3) Electroforming: After the mold has been treated, it is wrapped and connected to the wire.

(4) Demolding and reinforcement: After the electroforming part is formed, it needs to be reinforced with other materials because its strength is relatively low and it is very easy to deform. Common processing methods include: backing the mold sleeve, and then demolding or machining the electroforming part.

 

4. Practical Applications of Electroforming: Due to its outstanding mechanical properties, electroforming is primarily used in aerospace and precision manufacturing. Furthermore, electroforming does not require specialized equipment to produce a variety of screens and filters. Electroforming can also create holes of various shapes, with sizes reaching tens of millimeters.