Experimental investigations into ultrasonic-assisted jet electrodeposition process

In this study, a new process namely, ultrasonic-assisted jet electrodeposition, has been conceived. The ultrasonic-assisted jet electrodeposition process integrates the use of ultrasonic vibrations and high-speed selective jet electrodeposition process to fabricate micro shapes with comparatively high accuracy and with no edge effect. The present study focuses on the development of ultrasonic-assisted jet electrodeposition setup. The impacts of voltage, pulse on time of ultrasonic vibration, concentration of CuSO4·5H2O and interelectrode gap for the fabrication of square-shaped micro part have been studied. Deposition rate and dimensional accuracy of fabricated micro features were considered as responses. The experimental results showed that the ultrasonic-assisted jet electrodeposition process has the capability to fabricate micro parts, which yield better dimensional accuracy and no edge effect but waviness of the order of 10–50 µm, as compared to uneven depositional width and edge effect (gap of 200–250 µm) obtained by jet electrodeposition process.