Prediction of Grinding Force by an Electroplated Grinding Wheel with Orderly-Micro-Grooves

The ability to predict a grinding force is important to control,monitor,and optimize the grinding process.Few theoretical models were developed to predict grinding forces when a structured wheel was used in a grinding process.This paper aimed to establish a single-grit cutting force model to predict the ploughing,friction and cutting forces in a grinding process.It took into the consideration of actual topography of the grinding wheel,and a theoretical grinding force model for grinding hardened AISI 52100 by the wheel with orderly-micro-grooves was proposed.The model was innovative in the sense that it represented the random thickness of undeformed chips by a probabilistic expression,and it reflected the microstructure characteristics of the structured wheel explicitly.Note that the microstructure depended on the randomness of the protruding heights and distribution density of the grits over the wheel.The proposed force prediction model was validated by surface grinding experiments,and the results showed(1)a good agreement of the predicted and measured forces and(2)a good agreement of the changes of the grinding forces along with the changes of grinding parameters in the prediction model and experiments.This research proposed a theoretical grinding force model of an electroplated grinding wheel with orderly-micro-grooves which is accurate,reliable and effective in predicting grinding forces.

Mechanical Characterization of Electroplated Ni Films by Micro-tensile Testing

Mechanical properties of structural materials are particularly important for design, performance realization and reliability analysis of microelectromechanical systems （MEMS）. Furthermore, accurate database of mechanical properties at the micro scale can provide indispensable reference for establishing MEMS standard. Electroplated nickel film is one of the most favored structural materials used in MEMS, thus its mechanical properties has been studied for many years. However, the measured values show large scatter in Yotmg＇s modulus of nickel film. Young＇s modulus and yield stress of electroplated nickel film are measured by using a micro-tensile testing instrument. The tensile load applied on the specimen is measured by a load cell with accuracy 0.25 mN directly, without additional friction. Through measuring the axial stiffness coefficient of the tensile instnunent in situ, the tensile strain of the specimen is obtained by using two-serial spring model. The electroplated nickel films were fabricated from sulfarnate baths, and the gauge section is 500μm long and 10μm wide nominally, and thickness range between 25 μm and 50μm. The obtained Young＇s modulus from tensile testing is 83＋6 GPa for nickel specimens electroplated at current density of 20 mA/cm2 and it increases to 124＋5 GPa as current density is decreased to 10 mA/cm2. The phenomena are interpreted in terms of porosity of microstructure. The higher current density produced rnicrostucture with low density and high volume fraction of pores, and the microstructure of high porosity corresponds to a lower modulus. The measured values of Young＇s modulus are consistent with those of calculated from the exponential empirical formula between Young＇s modulus and porosity. The micro-tensile testing instrument can also be used for mechanical measurement of other MEMS films.

Effects of Electroplated Coatings on Corrosion Behavior of Ti-1023/30CrMnSiA Galvanic Couple

Galvanic corrosion behavior of Ti-1023 titanium alloy coupled 30CrMnSiA steel was investigated in 3.5% NaCl solution. Particular attention was given to the effect of three different electroplated coatings on corrosion behavior of the galvanic couple. Galvanic corrosion test was conducted on Ti-1023 titanium alloy which coupled Ni-electroplated 30CrMnSiA, Zn-electroplated 30CrMnSiA, Cd-electroplated 30CrMnSiA and bare 30CrMnSiA, respectively. Corrosion properties including open circuit potential （Eoc）, galvanic corrosion potential （Eg）, and galvanic corrosion current （lg） were monitored. Corrosion morphology was observed by optical microscope （OM） and corrosion mechanism was analyzed and discussed. The results show that the three electroplated coatings improve the corrosion resistance of the anode in different magnitudes. Ni-electroplated 30CrMnSiA and Cd-electroplated 30CrMnSiA coatings are found to be least susceptible to galvanic corrosion when coupled Ti-1023 titanium alloy. Zn-electroplated 30CrMnSiA is moderately susceptible to galvanic corrosion. But the bare 30CrMnSiA is highly susceptible to galvanic corrosion in corrosive environment.

Electron beam braze-welding of vanadium alloy to stainless steel with electroplated Cu/Ag coatings

Cracks may easily occur in the fusion weld between vanadium alloys and stainless steel due to the brittle intermetallics and welding stress. The high vacuum electron beam braze-welding has been successfully used to join vanadium alloy（V-5Cr-STi） to stainless steel （HR-2） with electroplated Cu and Ag coating. To investigate the effects of electroplated coating on the weldability, the joint appearaace, the microstrueture and the mechanical properties of the joints have been thoroughly analyzed. The results show that the joint surface configuration was good and root reinforcement was full and smooth. A reaction zone （RZ） was gained on the interface between the V-5 Cr-5 Ti alloy and HR-2 stainless steel base metals. The width of reaction zone at the top of the joint was up to O. 65 mm, wider than that in the bottom of the joint （ 0.46 mm）. The reaction zone consisted of considerably smaller dendritic structures with an average grain size of less than 10μm. Element Ag and Cu almost enriched the interface between V-SCr-5Ti alloy substrate and RZ, serving as a physical barrier which decreases or avoids the formation of intermetallics. The maximum tensile strength of vanadium alloy^stainless steel dissimilar alloy joint was more than 300 MPa. The joint was defects free.

Effect of mechanical attrition on microstructure and property of electroplated Ni coating

Ni coating was deposited on carbon steel by a mechanical attrition enhanced electroplating （MAEE） process. During the electroplating, the mechanical attrition（MA） was introduced by impact of glass balls on the sample surface with a special vibrating frequency. The surface and cross-sectional images of Ni coating were observed with SEM. The microstructure and crystallinity of coating were examined with TEM and XRD. The electrochemical performance of coating was measured with polarization curves and electrochemical impedance spectroscopy （EIS） and its mechanical behaviours, such as tensile strength and hardness, were studied. The results show that the MA has significant effects on the microstructure and property of the electroplated Ni coating. By MA, the coating becomes smooth, compact, thin and has refined grains and is free of cracks and pores. Consequently, the adhesion, tensile strength, hardness and corrosion resistance of coating are improved significantly.

Low field microwave absorption and magnetization process in CoFeNi electroplated wires

Ferromagnetic resonance （FMR）, Ferromagnetic antirresonance （FMAR） and low field magnetoimpedance （MI） are the characteristic features of high frequency losses in applied fields. While some results on FMR and FMAR in CoFeNi electroplated wires were reported earlier, here we present microwave absorption in CuBe wires electroplated by 1 μm FeCoNi magnetic layer at very low fields. These data are comparatively analysed together with longitudinal hysteresis loops in order to reveal the correlation between power absorption and magnetization processes. Microwave studies are made by using the cavity perturbation method at 9.65 GHz for a DC field parallel to the sample axis, and with microwave magnetic field hrf parallel or perpendicular to the wire axis. Two peaks have been observed in all samples, one is due to FMR, and the other is, at very low fields, related to MI. The MI peaks represent minima in power absorption. By comparing with the hysteresis loop we remark the close correspondence between the MI phenomena in the axial mode and the concomitant magnetization process.

Research on Cutting Trajectory of Electroplated Diamond Wire Saw

The cutting process of electroplated diamond wire saw was researched on the basis of impulse and vibration machining theories. The different contact states in the cutting process were analyzed by using the finite element method. It shows that the cutting stress is uniformly distributed along the direction of the workpiece width in the steady state. A mathematical equation of sawing trajectory was established by using the superposition principle and the cutting experiment of wire saw to calculate the cutting trajectory. The comparison of the theoretical trajectory with the calculated one indicates that the error is less than 15%. The research results provide a theoretic basis for optimization of the saw's cutting process parameters.

Microstructures and mechanical properties of electroplated Cu-Bi coatings

Electroplating has been used to produce Cu-Bi coatings. The crystal structure and lattice parameters of Cu in Cu-Bi composite coating were measured and compared with Cu coating. The mechanical properties of the coatings were also studied. It was found that the deposition parameters have significant effect on the mechanical properties of the Cu-Bi coatings. The microhardness has been improved from HVso165 of Cu coating to HVs0 250 of Cu-Bi composite coating prepared at 50 mA/cm2 for 20 min. Correspondingly, wear resistance of the Cu-Bi composite coating has also been enhanced significantly.

A new electroplated Ir/Ir(OH)_x pH electrode and its application in the coastal areas of Newport Harbor, California

Resulting from the rising levels of atmospheric carbon, ocean acidification has become a global problem. It has significant impacts on the development, survival, growth and physiology of marine organisms. Therefore, a high- precision sensor is urgently needed to measure the pH of sea-water. Iridium wire with a diameter of 0.25 mm is used as the substrate, and an Ir/Ir（OH）x pH electrode is prepared by a one-step electrochemical method in a LiOH solution at the room temperature. A scanning electron microscope （SEM） observation reveals that it is coated with nanoscale particles. In laboratory tests, the electrode exhibits a very promising pH response, with an ideal Nernst slope （56.14-59.52）, fast response, good stability and long fife-span in tested pH buffer solutions. For a sea trial, four pH electrodes and one Ag/AgC1 reference electrode are integrated with a self-made chemical sensor, and a profile detection of nearly 70 m is implemented near Newport Harbor, California on August 3, 2015. The results reflect that the pH value measured by the sensor is very close to the data given by Sea-Bird 911 plus CTD, with a difference value ranging from 0.000 075 to 0.064 719. And the sensor shows a better data matching degree in 0-40 m water depth. In addition, the high precision and accuracy of the sensor make it possible to use in the ocean observation field.

THE PREPARATION AND APPLICATION OF ELECTROPLATEDSHEET CONTAINING RS ALUMINUM ALLOY POWDERS

Baded on the study of nickel electroplating technology at room temperature, the plated sheet containing rapidly solidified Al-Fe-Cu- V-Si-Ni-Ce-Zr aluminum alloy powders is constructed successfully. The powders and nickel matrix are combined well in the sheet. It can be used to prepare the observation specimen for TEM and determine the hardness of single powder particle as solidified and after heat-treated. The advantages of this method are the realization of heat treatment of powders and the TEM observation of non-interfered microstructure of powders in the size of several microns.

Effect of Co-Deposited Iron on Microstructures and Properties of Electroplated Nanocrystalline Nickel-Iron Alloys

Nickel-iron nanocrystalline alloys with different compositions and grain sizes were fabricated by electroplating for MEMS devices. The iron content of the deposits was changed by varying the nickel/iron ion ratio in the electrolyte. X-ray diffraction (XRD) analysis was applied for measuring the strength of the texture and grain size of the deposits. The nickel/iron atom ratio of the deposits was analyzed by EDS. The hardness of the alloys was evaluated by Vickers hardness indenter. The internal stress of the deposits was measured by thin film stress measurement using Stoney's formula. Surface morphology and roughness were investigated by scanning electron microscopy (SEM) and atomic force microscopy (AFM). Hardness and internal stress mechanism of the electroplated structure as a function of Fe ion content and current density were revealed. With increasing the iron content, the hardness and internal stress of the deposits increase. An excellent correlation between the increase in the internal stress and the loss of (200) texture were found.

Sand-wear resistance of brush electroplated nanocomposite coating in oil and its application to remanufacturing

Sand-wear resistance of nano scale alumina particle reinforced nickel matrix composite coating （n-Al2O3/Ni） prepared by brush electroplating technique was investigated via wear tests in sand-contaminated oil lubricant, comparing with that of AISI1045 steel and brush electroplated Ni coating. Effects of testing load, sand content and sand size on worn volume of the three materials, and also coating surface roughness on worn volume of the brush electroplated coatings were accessed. Results show that the worn volume of all the three materials increases with increasing of testing load, sand content and sand size. In the same conditions, n-Al2O3/Ni composite coating has the smallest worn volume while AISI1045 steel has the largest because of the n-Al2O3 particle effects. As to n-Al2O3/Ni and Ni coatings, the surface-polished coatings have obviously lower worn volume than the as-plated coatings. The brush electroplated n-Al2O3/Ni composite coating was employed to remanufacture the sand-worn bearing seats of a heavy vehicle and good results were gained.

PREPARATION OF LEAD-ACID BATTERY USING ELECTROPLATED RETICULATED SiC AS THE POSITIVE CURRENT COLLECTOR

The possibility of using Pb-electroplated reticulated SiC as the positive current collector for lead-acid batteries was investigated. Reticulated SiC with two aperture sizes (3 and 2mm) were tested as the substrate of positive electrode. It was found that the reticulated SiC has an excellent corrosion resistance in H2SO4 solution, and the Pb layer electroplated on reticulated SiC showed analogous electrochemical behavior to metal Pb. Preliminary test of the battery performance indicated that the utilization efficiency of the positive active mass of new designed batteries are improved compared with the conventional batteries. The improvement could be ascribed to the high specific surface area of the reticulated structured positive current collector, which was further supported by the even better performance of the battery made from a smaller aperture size (2mm) reticulated SiC as the substrate of the positive electrode.

Formation and growth of Cu-Al IMCs and their effect on electrical property of electroplated Cu/Al laminar composites

Cu/Al laminar composite was prepared by dipping Zn layer and then electroplating Cu thick layer on pure Al sheet.During annealing the Cu/Al composites at temperature from 473 to 673 K, the Cu/Al interfacial diffusion and reaction and itskinetics and also the electrical resistivity of the composites were studied. The results show that no Cu?Al IMC layer is observable asthe composites are annealed at 473 K for time till 360 h, indicating that the Zn intermediate layer can effectively suppress the Cu/Alinterfacial diffusion. However, as the composites are annealed at 573 K and above, Zn atoms in the Zn layer dissolve into the Culayer. Tri-layered reaction product of CuAl2/CuAl/Cu9Al4 then forms from the Al side to the Cu side. The IMC layer follows thediffusion-controlled growth kinetics. Electrical resistivity of the Cu/Al composites increases with the increase of the annealingtemperature and time.

Tribological Characteristics of Chromium-active Carbon Electroplated Composite Coatings

A process of chromium electroplating using a standard bath with additives and active carbon particles was reported,and the tribological behaviors of the composite coatings using the pin-on-disk tester and the table wear tester were investigated.Experimental results indicate that the electroplated chromium-active carbon composite coatings exhibited the low friction coefficient and excellent anti-wear properties when compared with the normal chromium electroplated ones.The formation of active carbon particles within the chromium matrices can be explained by SEM analysis and the mechanisms of wear resistance of the composite coatings were studied.

Relationship between dispersibility of ZrO2 nanoparticles in Ni-ZrO2 electroplated nanocomposite coatings and mechanical properties of nanocomposite coatings

Ni-ZrO2 nanocomposite coatings with monodispersed ZrO2 nanoparticles were prepared from the composite plating bath containing dispersant under DC electrodeposition condition. It is found that the morphology, orientation and hardness of the composite coating with monodispersed ZrO2 nanoparticles have lots of difference from the composite coating with agglomerated ZrO2 nanoparticles and pure nickel coating. Especially, the result of hardness shows that only a very low volume fraction (less than 1%) of monodispered ZrO2 nanoparticles in Ni-ZrO2 composite coatings will result in higher hardness of the coating. The hardness of Ni-ZrO2 nanocomposite coatings with monodispersed and agglomerated ZrO2 nanoparticles are HV 529 and HV 393, respectively. The hardness value of the former composite coatings is over 1.3 times higher than that of the later. All these composite coatings are 2 - 3 times higher than that of pure nickel plating (HV 207) prepared under the same conditions.

STUDY ON THE REAR CAPACITY OF DEPOSITS USING ELECTROLESS NICKEL DEPOSITION AND ELECTROPLATE CHROMIUM

The comparison study of the relations between the hardness, wear capacity and heat treatment temperature of the electroless nickel deposition with the electroplating deposits of chromium were conducted .The results showed that the hardness and wear capacity of the electroplate technology were superior than that of electroless in general cases, but with the raising of the heat treatment temperature, the hardness and wear capacity of the samples treated by electroless deposition technology were superior obviously than that of electroplate.

Performance evaluation of creep feed grinding ofγ-TiAl intermetallics with electroplated diamond wheels

This paper evaluates the performance of creep feed grindingγ-TiAl intermetallic(Ti-45 Al-2 Mn-2 Nb)using electroplated diamond wheels.Firstly,a comparative analysis with the grinding results by using electroplated CBN wheels was conducted,mainly involving abrasive wheel wear behavior and maximum material removal rate below surface burn limit.It was found that the diamond wheel would produce much better grinding results including lower wheel wear rate and higher maximum material removal rate.Then the surface integrity obtained at different level of material removal rate was characterized with the utilization of the diamond wheel.The poor ductility of thisγ-TiAl intermetallic material was found to have a marginal effect on the surface integrity,as no severe surface defects such as material pullout were generated during the stable wheel wear stage.For the involved operating parameters,a deformation layer was produced with~10μm or more in thickness depending on the material removal rate used.Meanwhile,a work-hardened layer extending to more than 100μm was produced with a maximum microhardness of above 520 HV0.05(bulk value 360 HV0.05).The residual stress remained compressive,with a value of above-100 MPa and even up to-500 MPa for an elevated material removal rate.Shearing chip was the main chip type,indicating good wheel sharpness in the grinding process.

Effect of laser-discrete-quenching on bonding properties of electroplated grinding wheel with AISI 1045 steel substrate and nickel bond

To improve the bonding strength between the nickel bond and the hub of the electroplated diamond grinding wheel,a hybrid technique was proposed to combine laser prequenching steel substrate and post-electroplating nickel.To validate the effectiveness of the proposed technique,AISI 1045 substrate was nickel-coated.The bonding properties between the electroplated nickel coating and substrate with or without laser-discrete-quenching were discussed comparatively by scratch,indentation,and thermal shock tests.The results show that the prequenching treatment leads to phase transformation of AISI 1045 microstructure from the mixed pearlite and ferrite phases into the martensitic phase.Since the martensitic phase is characterized as a high corrosion resistance,the interface of substrate/coating is smooth and flat in the prequenched zone,and the coating is bonded well with the steel substrate.In contrast to the steel substrate without pre-quenching treatment,the proposed technique significantly enhanced the bonding strengths of the electroplated nickel-coating.On one hand,the average hardness of electroplated nickel-coating on the laser pre-quenched zone is increased by 18.7%,and the scratch depth with the same load become narrower and shallower.On the other hand,the coefficient of friction(CoF)and the vibration amplitude are reduced,and the coating is bonded effectively with the substrate to inhibit the crack initialization at the interface.This prevents effectively the coating from peeling off and improves significantly the thermal shock resistance property.

Surface Metallization of Glass Fiber(GF)/Polyetheretherketone(PEEK) Composite with Cu Coatings Deposited by Magnetron Sputtering and Electroplating

Surface metallization of glass fiber(GF)/polyetheretherketone(PEEK)[GF/PEEK] is conducted by coating copper using electroplating and magnetron sputtering and the properties are determined by X-ray diffraction(XRD), scanning electron microscopy(SEM), and electron backscatter diffraction(EBSD).The coating bonding strength is assessed by pull-out tests and scribing in accordance with GB/T 9286-1998.The results show that the Cu coating with a thickness of 30 μm deposited on GF/PEEK by magnetron sputtering has lower roughness, finer grain size, higher crystallinity, as well as better macroscopic compressive stress,bonding strength, and electrical conductivity than the Cu coating deposited by electroplating.