SGER: Feasibility Study of Nano-Electrochemical Machining Process

University Of Nebraska-Lincoln, Lincoln NE

Investigators

Abstract

Extensive research in Nanoscience and Nanotechnology in various fields such as biology, optics, telecommunication, material and electronics promises novel and sustainable technologies and products. To fulfill the promise, a set of new manufacturing processes and manufacturing paradigms are needed for industrial scale production. A recently conducted NSF workshop on Nonomanufacturing and Processing recommends bottom up (such as electroforming and assembly) and top down (such as EDM, ECM, laser and etching) processes as potential technologies for generating 1D, 2D, and 3D nanostructures and devices. This SGER proposal seeks funding to study the feasibility of developing a Nano-Electrochemical Machining (Nano-ECM) process. Electrochemical machining (ECM) process, an anodic dissolution process, selectively removes material atom by atom and thus avoids post-processing operations. As ECM is a non-thermal and non-mechanical contact process, it generates burr-free and stress-free surfaces. Micro-ECM process has shown to be highly successful in machining arbitrary 3D micro shapes. Therefore, ECM seems an ideal candidate as one of the top down nanomachining processes. However, many scientific and technical barriers and associated risks must be considered and addressed for the realization of Nano-ECM process. Intellectual Merit: This study will establish an extensive and comprehensive knowledge base of the state-of-the art research in electrochemical deposition and dissolution at nanoscale and related scientific and technical barriers. An attempt will be made to develop a mathematical model to describe Nano-ECM process by taking into consideration mass transport process at a very small gap, coupled modes of mass transport, coupling of Faradic processes and statistical aspects of discrete events of reactions. A Nano-ECM cell will be assembled using an Atomic Force Microscope (AFM). Broader Impacts: This study will initiate the establishment of an educational and research infrastructure for Nanomanufacturing at the University of Nebraska-Lincoln (UNL) that will be accessible to researchers from UNL and other U.S. universities. The success of the project will lead to the development of a new graduate/undergraduate course on Nanomanufacturing. The project results will be demonstrated to high school teachers and students on a regular basis. A collaborative research with researchers at the Warsaw University of Technology will be planned by simultaneously submitting proposals to US and EU research agencies.