Thermal spray and cold spray analysis of density, porosity, and tensile Specimens for use with LIGA applications

Technical Report · Mon Jan 31 23:00:00 EST 2000

DOI:https://doi.org/10.2172/752018· OSTI ID:752018

DECKER, MERLIN K ^[1]; SMITH, MARK F

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1. Sandia National Laboratories

This analysis provides a preliminary investigation into using Twin-Wire Arc Thermal Spray and Cold Spray as material deposition processes for LIGA applications. These spray material processes were studied to make an initial determination of their potential as alternatives to producing mechanical parts via the electroplating process. Three materials, UltraMachinable{reg_sign} Stainless Steel, BondArc{reg_sign}, and aluminum, were sprayed using Thermal Spray. Only aluminum was sprayed using the Cold Spray process. Following the spray procedure, the test specimens were released from a copper mold and then tested. Three tests, density, tensile strength, and porosity, were performed on the specimens to determine the spray effect on material properties. Twin-Wire Arc Thermal Spray did not demonstrate adequate deposition properties and does not appear to be a good process candidate for LIGA. However, Cold Spray yielded better density results and warrants further investigation to analyze the minimum feature size produced by the process.

• Research Organization: Sandia National Labs., Albuquerque, NM (US); Sandia National Labs., Livermore, CA (US)
• Sponsoring Organization: US Department of Energy (US)
• DOE Contract Number: AC04-94AL85000
• OSTI ID: 752018
• Report Number(s): SAND2000-0339
• Country of Publication: United States
• Language: English

Related Subjects

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
36 MATERIALS SCIENCE
ALUMINIUM
COATING
COLD SPRAY
DENSITY
ELECTROPLATING
FLAME SPRAY
FLAME SPRAYING
LIGA
MANUFACTURING
MECHANICAL PROPERTIES
MECHANICAL PROPERTIES OF COATINGS
POROSITY
SPRAY COATING
STAINLESS STEELS
TENSILE PROPERTIES
THERMAL SPRAY
TWIN-WIRE ARC THERMAL SPRAY