Research Papers

Roll Molding of Microchannel Arrays on Al and Cu Sheet Metals: A Method for High-Throughput Manufacturing

[+] Author and Article Information
Bin Lu

e-mail: blu2@lsu.edu

W. J. Meng

e-mail: wmeng1@lsu.edu
Department of Mechanical and
Industrial Engineering,
Louisiana State University,
2508 Patrick F. Taylor Hall,
Baton Rouge, LA 70803

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF Micro- AND Nano-Manufacturing. Manuscript received July 3, 2013; final manuscript received November 6, 2013; published online December 4, 2013. Assoc. Editor: Ashutosh Sharma.

J. Micro Nano-Manuf 2(1), 011007 (Dec 04, 2013) (9 pages) Paper No: JMNM-13-1053; doi: 10.1115/1.4025978 History: Received July 03, 2013; Revised November 06, 2013

The method of roll molding is proposed as an alternative to compression molding for low-cost, high-throughput manufacturing of metal-based microchannel structures. Elemental aluminum- and copper- based microchannel arrays with depths of ∼600 μm and depth:width ratios ≥2:1 were successfully fabricated by roll molding at room temperature. Morphologies of roll molded Al and Cu microchannels were examined in detail. Response of roll molding was characterized by measuring depths of roll molded microchannels as a function of the normal loading force per width. This response of roll molding was further shown to scale with the flow stress of roll molded material. Roll molding offers the potential of fabricating microchannel structures with large footprints in a continuous manner.

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Fig. 1

A schematic for making microchannel arrays on sheet metals by rolling molding

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Fig. 2

Inconel roller sleeve for roll molding of microchannels: (a) schematic of a roller sleeve containing an array of circumferential microprotrusions; (b) an optical image of the microprotrusion array on the W-C:H coated Inconel roller sleeve after multiple Al roll molding runs; and (c) nominal dimensions of the microprotrusions on the roller sleeve

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Fig. 3

SE images of typical microprotrusions on the Inconel X750 roller sleeve: (a) before W-C:H coating and (b) after W-C:H coating

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Fig. 4

A schematic of plane strain rolling of flat metal strips

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Fig. 5

Flow stress versus strain obtained from microhardness measurements on as-annealed and rolled Al strips: (a) data for 2.2 mm thick Al strips and (b) data for 1.0 mm thick Al strips

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Fig. 6

Thickness reduction ratio versus normal loading force per width: a comparison between experimental data and solution to the von Karman equation for the 2.2 mm thick Al strips

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Fig. 7

Thickness reduction ratio versus normal loading force per width: a comparison between experimental data and solution to the von Karman equation for the 1.0 mm Al strips

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Fig. 8

Overview of typical roll molded microchannel arrays on surfaces of Al and Cu strips: (a) Al and (b) Cu

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Fig. 9

Close-up view of typical roll molded microchannels on surfaces of Al and Cu strips: (a) Al and (b) Cu

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Fig. 10

Cross-sectional ISE images of a typical roll molded Cu microchannel: (a) channel geometry and grain structure and (b) close-up view near channel bottom corners showing pattern of material flow during roll molding

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Fig. 11

Depths of Al and Cu microchannels versus the normal loading force per width

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Fig. 12

Depths of Al and Cu microchannels versus the total applied torque

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Fig. 13

Cross section profile of roll-molded microchannel arrays: (a) in Al and (b) in Cu

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Fig. 14

Longitudinal elongation versus microchannel depth

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Fig. 15

Microchannel depth versus normal loading force per width, normalized by flow stresses of as-annealed Al and Cu strips, 101 ± 6 MPa and 278 ± 18 MPa, respectively

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Fig. 16

Normalized flow stress versus strain for Al and Cu strips: flow stresses at different strains were normalized by the flow stress at zero strain




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