Optics and Precision Engineering, Volume. 32, Issue 13, 2091(2024)
Additive regulated electrochemical microfluidic beam 3D printing
Figures & Tables(17)
Fig. 1. Morphology of microfluidic beam deposition with different proportions of additives
Fig. 2. Finite element simulation model of microbeam electrolysis system
Fig. 3. Numerical simulation of microbeam electrolysis system deposition of copper columns for 40 minutes（legend indicating the flow velocity of the liquid beam and arrow indicating the current vector）
Fig. 4. Deposition velocity distribution curves of cathode surface with different deposition heights
Fig. 5. Schematic diagram of electrochemical 3D printing experimental platform
Fig. 7. Response surface model of factors
Table 1. Single additive variable deposition morphology and formation reasons
View tableView in ArticleTable 1. Single additive variable deposition morphology and formation reasons
SPS/PEG/Cl- Morphology characteristics Formation reasons Excess SPS Dark red or black， non-glossy coating in low current density regions； numerous pits in high current density regions Excess SPS inhibits copper crystallization Low SPS Non-glossy in low current density regions， not burnt in high current density regions， small glossy area Insufficient SPS on the cathode surface to form a glossy area Excess PEG Glossy in high and medium current density regions， rough in low current density regions PEG cannot inhibit hydrogen evolution in low current density regions Low PEG Poor leveling and glossiness in high and medium current density regions The consumption rate of PEG molecules during electrodeposition is less than the diffusion rate of the leveling agent from the solution to the electrode surface Excess Cl- Red deposition morphology in high， medium， and low current density regions "Chlorine bridge" effect between copper ions and chloride ions increases polarization current Low Cl- Sponge-like burnt appearance in high current density regions Lack of CuCl- film formation on the cathode metal surface
Table 2. Domain definitions and boundary conditions for microbeam electrolysis system simulation
View tableView in ArticleTable 2. Domain definitions and boundary conditions for microbeam electrolysis system simulation
Boundary condition Boundary Property Anode surface 2，8 Φs，ext=3 V Cathode surface 5 Φs，ext=0 V Insulation 3，7 - Specified normal grid velocity 5 Vn Zero normal grid velocity 4，6 - Inlet 1 U0=1 m/s Outlet 4，6 - Steady-state free surface 3，7 -
Table 3. Value of controllable factors on different levels
View tableView in ArticleTable 3. Value of controllable factors on different levels
Factors Level 1 Level 2 Level 3 SPS Concentration/10-6 10 40 70 PEG Concentration/10-6 50 100 150 Cl- Concentration/10-6 30 60 90 CuSO4/（g·L-1） 40 70 100 H2SO4/（g·L-1） 150 180 210
Table 4. Orthogonal test result created by Minitab
View tableView in ArticleTable 4. Orthogonal test result created by Minitab
No. SPS/10-6 PEG/10-6 Cl-/10-6 CuSO4/（g·L-1） H2SO4/（g·L-1） Surface-ness/Sa 1 10 50 30 40 150 21 2 10 50 30 70 180 22.68 3 10 50 30 100 210 20.04 4 10 100 60 40 180 11.28 5 10 100 60 70 210 10.68 6 10 100 60 100 150 12.12 7 10 150 90 40 210 22.44 8 10 150 90 70 150 23.64 9 10 150 90 100 180 22.44 10 40 100 90 40 150 14.06 11 40 100 90 70 180 16.53 12 40 100 90 100 210 13.11 13 40 150 30 40 180 17.765 14 40 150 30 70 210 18.715 15 40 150 30 100 150 16.815 16 40 50 60 40 210 16.91 17 40 50 60 70 150 15.58 18 40 50 60 100 180 13.775 19 70 150 60 40 150 20.88 20 70 150 60 70 180 22.08 21 70 150 60 100 210 18.48 22 70 50 90 40 180 17.76 23 70 50 90 70 210 21.36 24 70 50 90 100 150 22.68 25 70 100 30 40 210 12.96 26 70 50 30 70 150 16.44 27 70 50 30 100 180 21.36
Table 5. Response surface analysis factors and levels
View tableView in ArticleTable 5. Response surface analysis factors and levels
Factor Code Conversion formula between encoded and real values Level Encoded value Real value -1 0 1 SPS/10-6 A a A=（a-40）/10 30 40 50 PEG/10-6 B b B=（b-100）/20 80 100 120 C c C=（c-60）/20 40 60 80 Current amplitude /mA D d D=（d-7.5）/2.5 5 7.5 10
Table 6. Response surface analysis scheme and test results
View tableView in ArticleTable 6. Response surface analysis scheme and test results
No. SPS/10-6 PEG/10-6 Cl-/10-6 Current
amplitude
/mA
Surface
roughness
/μm
No. SPS/10-6 PEG/10-6 Cl-/10-6 Current
amplitude
/mA
Surface roughness
/μm
1 40 100 60 7.5 1.17 15 30 100 40 7.5 15.74 2 50 100 80 7.5 5.59 16 40 100 40 10 5.24 3 40 80 60 10 8.93 17 40 120 60 10 2.54 4 50 100 60 5 10.87 18 40 80 40 7.5 15.24 5 30 80 60 7.5 16.54 19 40 120 60 5 6.04 6 30 100 60 10 9.76 20 40 120 80 7.5 8.34 7 40 100 80 10 6.84 21 30 120 60 7.5 8.88 8 40 120 40 7.5 4.06 22 30 100 80 7.5 11.34 9 40 100 40 5 7.52 23 50 100 60 10 5.56 10 30 100 60 5 8.24 24 40 100 60 7.5 0.07 11 40 100 80 5 6.31 25 50 100 40 7.5 11.24 12 50 120 60 7.5 8.51 26 50 80 60 7.5 11.89 13 40 80 60 5 12.45 27 40 100 60 7.5 0.69 14 40 80 80 7.5 7.42
Table 7. Results of variance analysis of surface roughness
View tableView in ArticleTable 7. Results of variance analysis of surface roughness
Source Df Mean square F-value P-value Model 14 33.22 13.04 <0.000 1** A-SPS 1 23.80 9.34 0.010 0* B-PEG 1 98.04 38.47 <0.000 1** C-Cl- 1 14.08 5.53 0.036 7* D-Current amplitude 1 18.08 5.53 0.036 7* AB 1 4.84 1.90 0.193 3 AC 1 0.422 5 0.165 8 0.691 1 AD 1 11.56 4.54 0.054 6 BC 1 36.60 14.36 0.002 6** BD 1 0.010 0 0.003 9 0.951 1 CD 1 2.25 0.882 8 0.366 0 A² 1 207.50 81.42 <0.000 1** B² 1 113.47 44.52 <0.000 1** C² 1 78.03 30.62 <0.000 1** D² 1 21.87 8.58 0.012 6* Lack of fit test 10 3.00 9.88 0.095 3
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Yong LIU, Shengyang XU, Lixiaoxue CHEN, Wanlu LI, Pengfei DONG. Additive regulated electrochemical microfluidic beam 3D printing[J]. Optics and Precision Engineering, 2024, 32(13): 2091
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Received: Mar. 13, 2024
Accepted: --
Published Online: Aug. 28, 2024
The Author Email: LIU Yong (rzliuyong@163.com)
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