基于复杂型面薄壁零件成形的电铸试验研究

 在航空、航天领域存在诸如风洞喷管、波导元件和叶片电极等异型薄壁零件,采用常规加工方法对这些薄壁零件进行加工时存在着难加工的问题,利用一种新型的电铸技术——阴极平动式游离粒子辅助磨擦电铸技术对其进行直接成形加工。在电铸过程中,阴阳极之间添加不导电的游离粒子,随着阴极的不断运动,游离粒子能够周期性地对电沉积层产生磨擦、抛光、挤压作用,以此来提高表面质量,强化电铸层。与传统电铸技术所制备的电铸镍层进行了对比试验,试验结果表明：游离粒子辅助磨擦电铸技术能够获得表面光亮、平整电铸层;电铸层（200）晶面的衍射强度明显降低,（111）和（220）晶面的衍射强度显著提高;电铸层的机械性能也得到了明显的改善,显微硬度和抗拉强度比传统电铸工艺提高了一倍左右。以此为基础，成功制备了复杂型面叶片阴极,其显微硬度和表面粗糙度都得到了明显改善。

Experimental Research on Electroforming of Complex Parts with Thin Wall

In order to solve the problems in traditional machining of complex parts with thin wall such as nozzle, waveguide component and blade electrode in the fields of aeronautics and astronautics, a novel technique of free particles polishing electroforming with orbital movement cathode is put forward. Free particles are added between cathode and anode. The cathode moves with the orbital movement. The effect of periodic abrasion, polishing and squeezing of the free particles on the electro decomposition layer can improve the surface quality and strengthen the electroforming coating. In a comparison with the samples produced by traditional electroforming method, the free particles polishing electroforming is found to be able to obtain bright and smoothing surface. The intensity of (200) reduces and that of (111) and (220) increase significantly. The mechanical property of the coating is greatly improved due to the polishing and squeezing of the free particles. The micro hardness doubles and the tensile intensity increases by over 90%. Based on the experimental results, complex blade cathodes are produced successfully. Both micro hardness and surface roughness of the complex parts are improved significantly.