Desenvolvimento e caracterização de sistema de eletrodeposição por jato para manufatura aditiva eletroquímica: investigação experimental dos efeitos de parâmetros de processo na qualidade de depósitos de cobre

Abstract

Electrochemical Additive Manufacturing (ECAM) is an emerging technology with the potential to revolutionize the microfabrication of metallic components. This thesis focuses on the development and characterization of a jet electrochemical deposition (Jet-ECD) system for copper ECAM, investigating the effects of process parameters on deposit quality. The main objective was to model the influence of nozzle feed rate, current density, inter-electrode distance, and electrolyte flow rate, as well as solution composition, on the deposition rate, morphology, microstructure, and mechanical properties of copper deposits. The research developed a robust and automated Jet-ECD system, enabling systematic process investigation. The methodology involved multiscale characterization of deposits through laser interferometry, scanning electron microscopy (SEM), and Vickers microhardness testing. The results established quantitative correlations between process parameters and deposit characteristics, revealing that electric current is the dominant parameter with nonlinear behavior. Feed rate and electrolyte composition also showed significant influences on morphology and process stability. The experimental results demonstrated a wide variability in the properties of copper deposits as a function of the investigated process parameters. The arithmetic mean deviation of the assessed roughness profile (Ra) ranged from 0.6 μm to 2.0 μm, demonstrating greater sensitivity to variations in electric current. The arithmetic mean deviation of the assessed waviness profile (Wa) ranged from 1.1 μm to 4.3 μm, evidencing sensitivity to the hydrodynamic parameters of the process. The deposition rate fluctuated between 0.008 mg/min and 0.068 mg/min, with maximum values obtained under the highest electric current analyzed (6 mA) and the highest feed rate analyzed (1.4 mm/min). The grain size of the polycrystalline deposits varied from 0.8 μm to 1.2 μm, indicating a relatively fine microstructure controllable by the electrodeposition parameters. The Vickers microhardness showed significant variation, ranging from 100 HV to 170 HV, with maximum values of 170 HV obtained under 4 mA current and 0.6 mm/min feed rate, demonstrating the ability to tailor mechanical properties through process parameter control. It was concluded that the study provides relevant technological, scientific, and methodological contributions to the consolidation of Jet-ECD as an advanced manufacturing technology, demonstrating its capability to produce materials with controllable properties.