Effects of Current Density and Frequency on Microstructure and Mechanical Properties of Ni Stencil Masks Fabricated by Pulse Electroforming

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We fabricated Ni stencil masks using a pulse electroforming and investigated the effects of current density and frequency on the microstructure and mechanical property. In the electroforming process, the current densities were 2.5 and 5 A/dm2 and the frequency varied from 0 (DC) to 1000 Hz at a duty cycle of 50%. Texture, microstructure, and mechanical properties varied with the current density and frequency. The preferred orientation of (220) at 2.5 A/dm2 changed to (200) as the current density increased to 5 A/dm2. Grain size decreased with decreasing current density or increasing frequency, probably due to a sufficient supply of Ni ions and the presence of inhibitor species. This decrease in grain size resulted in increase of hardness and wear resistance. However, with increase in current density and frequency (5 A/dm2 and 1000 Hz), the grain size became large, as a result of faradic current during the off-time.
2012-09-25