Research on micro-electric resistance slip welding of copper electrode during the fabrication of 3D metal micro-mold

a b s t r a c t 3D micro-mold fabricated by the micro double-staged laminated object manufacturing process (micro- DLOM) is formed via stacking and fitting of multi-layer 2D micro-structures. The connection of 2D micro-structures is related to forming accuracy and mechanical properties of 3D micro-mold. In this research, micro-electric resistance slip welding of copper electrodes was proposed to connect multi- layer 2D micro-structures. Firstly, the proper process parameters of slip welding were obtained through the welding experiment, and the temperature field of micro-electric resistance slip welding under such process parameters was simulated. Secondly, deposition effect of the copper bar electrode produced during slip welding was studied and the study results show that the copper element deposited in the slip welding area decreases as the surface roughness of copper electrode decreases. Finally, based on the above research, a square micro-cavity mold with micro-channel, a circular micro-cavity mold with cross keyway and micro gear cavity mold with two-stage steps were welded by the micro-electric resistance slip welding. © 2013 Elsevier B.V. All rights reserved.

[1]  Bin Xu,et al.  Fabrication of 3D metal micro-mold based on femtosecond laser cutting and micro-electric resistance slip welding , 2013 .

[2]  Xinmin Lai,et al.  Electrical-assisted embossing process for fabrication of micro-channels on 316L stainless steel plate , 2013 .

[3]  Di Zhu,et al.  Micro electrochemical milling of complex structures by using in situ fabricated cylindrical electrode , 2012 .

[4]  Yong-Kyu Yoon,et al.  Multidirectional UV Lithography for Complex 3-D MEMS Structures , 2006, Journal of Microelectromechanical Systems.

[5]  George K. Knopf,et al.  Non-lithographic fabrication of metallic micromold masters by laser machining and welding , 2012 .

[6]  M. A. Habib,et al.  Fabrication of complex shape electrodes by localized electrochemical deposition , 2009 .

[7]  Jingfeng Li,et al.  Fabrication and evaluation of microscale thermoelectric modules of Bi2Te3-based alloys , 2010 .

[8]  G. Reisse,et al.  Microstructuring of Steel and Hard Metal using Femtosecond Laser Pulses , 2011 .

[9]  Shih-Feng Tseng,et al.  Glass biochip fabrication by laser micromachining and glass-molding process , 2012 .

[10]  S. Büttgenbach,et al.  Novel 3D manufacturing method combining microelectrial discharge machining and electrochemical polishing , 2012 .

[11]  Jingfeng Li,et al.  Microfabrication of thermoelectric modules by patterned electrodeposition using a multi-channel glass template , 2011 .

[12]  Volker Schulze,et al.  Increase of process reliability in the micro-machining processes EDM-milling and laser ablation using on-machine sensors , 2012 .

[13]  T. Mineta,et al.  Micromachining of electroformed nickel mold using thick photoresist microstructure for imprint technology , 2008 .

[14]  Hollow metallic microneedles fabricated by combining bulk silicon micromachining and UV–LIGA technology , 2012 .

[15]  D. Guo,et al.  Micro machining of pre-sintered ceramic green body , 2012 .

[16]  S. Ruan,et al.  Study on tungsten electrode deposition effect of 3D metal micro-mold during laminated slip welding , 2013 .