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Andreou E, Roy S. Modelling the Scaling-Up of the Nickel Electroforming Process. FRONTIERS IN CHEMICAL ENGINEERING 2022. [DOI: 10.3389/fceng.2022.755725] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022] Open
Abstract
Electroforming is increasingly gaining recognition as a promising and sustainable additive manufacturing process of the “Industry 4.0” era. Numerous important laboratory-scale studies try to shed light onto the pressing question as to which are the best industry approaches to be followed towards the process’s optimisation. One of the most common laboratory-scale apparatus to gather electrochemical data is the rotating disk electrode (RDE). However, for electroforming to be successfully optimised and efficiently applied in industry, systematic scale up studies need to be conducted. Nowadays, well-informed simulations can provide a much-desired insight into the novelties and limits of the process, and therefore, scaling up modelling studies are of essence. Targeted investigations on how the size and geometry of an electroforming reactor can affect the final product could lead to process optimisation through simple modifications of the setup itself, allowing immediate time- and cost-effective adjustments within existing production lines. This means that the accuracy of results that any scaled up model provides, if compared to a successful, smaller scale version of itself, needs to be investigated. In this work a 3-D electrodeposition model of an RDE was used to conduct geometry and model sensitivity studies using a commercial software as is often done in industry. As a next step, a 3-D model of an industrial-scale electroforming reactor, which was 90 times larger in electrolyte volume compared to the RDE, was developed to compare, and identify the key model parameters during scale up. The model results were validated against experimental data collected in the laboratory for both cases to assess model validity.
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Yamaguchi G, Motoyama H, Owada S, Kubota Y, Egawa S, Kume T, Takeo Y, Yabashi M, Mimura H. Copper electroforming replication process for soft x-ray mirrors. THE REVIEW OF SCIENTIFIC INSTRUMENTS 2021; 92:123106. [PMID: 34972441 DOI: 10.1063/5.0065684] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/04/2021] [Accepted: 12/06/2021] [Indexed: 06/14/2023]
Abstract
We developed a copper electroforming replication (CER) process to fabricate precise ellipsoidal mirrors for soft x-ray focusing. Some applications of ellipsoidal mirrors in x-ray microscopy require that all components that are close to samples, including the mirrors, are made of non-magnetic materials. In this study, a non-magnetic copper ellipsoidal mirror was fabricated by replicating a figured and super-polished quartz glass mandrel using an electroforming technique. It was found that the CER process has a high replication accuracy of 8 nm. The focusing performance of the mirror was characterized using a soft x-ray free-electron laser with a photon energy of 100 eV. A small focus size of 370 × 400 nm2 was achieved with a high reflectivity of 65%.
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Affiliation(s)
- Gota Yamaguchi
- Department of Precision Engineering, School of Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
| | - Hiroto Motoyama
- Department of Chemistry, School of Science, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-0033, Japan
| | - Shigeki Owada
- Japan Synchrotron Radiation Research Institute, 1-1-1 Kouto, Sayo-cho, Sayo-gun, Hyogo 679-5198, Japan
| | - Yuya Kubota
- RIKEN SPring-8 Center, 1-1-1 Kouto, Sayo-cho, Sayo-gun, Hyogo 679-5148, Japan
| | - Satoru Egawa
- RIKEN Center for Advanced Photonics, 2-1 Hirosawa, Wako, Saitama 351-0198, Japan
| | - Takehiro Kume
- Technology Center, Natsume Optical Corporation, 1200-29 Kawaji, Iida, Nagano 399-2431, Japan
| | - Yoko Takeo
- Japan Synchrotron Radiation Research Institute, 1-1-1 Kouto, Sayo-cho, Sayo-gun, Hyogo 679-5198, Japan
| | - Makina Yabashi
- Japan Synchrotron Radiation Research Institute, 1-1-1 Kouto, Sayo-cho, Sayo-gun, Hyogo 679-5198, Japan
| | - Hidekazu Mimura
- Department of Precision Engineering, School of Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan
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TAKEI Y, MIMURA H. System Development for Fabricating Mandrel of Soft X-ray Rotating-Body Mirror (1st Report). ACTA ACUST UNITED AC 2017. [DOI: 10.2493/jjspe.83.245] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
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