JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 56

KNOW-HOW
Mould

Electroformed moulds:
fabrication and applications
Electroformed moulds consist of an extra-hard nickel shell over a steel frame, making it possible to mould many times more than with a composite mould. The technology is particularly well suited to RTM processes and prepreg moulding.

VINCENT BELORGEOT PRESIDENT CORIMA TECHNOLOGIES SAS

orima Technologies is a French mould maker specializing in electroformed nickel moulds. In 2009, after 13 years of experience producing moulds sized 3 x 2.5 x 2 m and smaller, the company decided to double the volume of its electroforming baths and tank size so as to be able to offer large moulds sized 7 x 4 x 2.5 m. The change will enable Corima Technologies to keep up with the demand for moulds for large composite parts. The electroformed nickel moulds consist of a 5mm-thick nickel shell mounted on a mechanically welded frame, so they combine the advantages of high-temperature composite moulds with those of metal ones.

C

Fig. 1: Electroforming process

electrodes – that are immerged in a metal-rich solution, metal atoms are deposited on the electrode connected to the negative pole in what is called an electrolytic reaction. This process is used at a larger scale to produce nickel moulds (Fig. 1).

Overview of the electroforming principle
Electroforming, or electrodeposition, consists in using electrolysis to deposit a metal on a conductive surface. In the case of moulds, nickel is the most suitable pure metal (only a pure metal can be electrolysed). For reference, consult the March-April 2007 issue (JCM 31) of JEC Composites Magazine. When a current is applied between two conductive elements – the

Manufacturing process for a nickel lay-up tool
Corima starts with the part’s CAD design and specifications to create a design study that defines the mould surface, the support frame and all accessories required for moulding the composite part, e.g. the vacuum system, thermocouples, tooling holes, and laser targets (Fig. 2).

Nickel mould properties
- Nickel hardness: 15 HRC - Reproduction accuracy (leather graining, various textures) - Corrosion resistance - High thermal conductivity - Wear resistance - Possible to adjust mould shape (compensating for springback without resorting to machining) - A good solution for deep shapes or complex parts - Moulds with a lightweight structure, leading to higher productivity (shorter cycle times and larger series) - Meticulous surface finishing (mirror finishes, Class A body parts)

56

jec composites magazine / No57 May 2010



JEC COMPOSITES MAGAZINE - Issue #57 - May 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #57 - May 2010

Cover
Editorial
Market Place
Advertisers
Index
Contents
NEWS WORLDWIDE
- Companies
- Agenda of events
- Equipment
BUSINESS
- Market survey
- Trends
- Niche Market
- Human Capital
FEATURE - AUTOMATION
- 3D X-ray
- Process
- CNC
- Control
- FCS
- Filament winding
- Robotics
USERS' PLATFORM
- Composites in the world
- Successful Partners
- Application
KNOW-HOW
- Preform Control
- Thermoplastics
- Mould
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Cover
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 2
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Editorial
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Market Place
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Index
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - Contents
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 7
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Companies
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Agenda of events
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Equipment
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 11
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 12
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 13
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 14
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - BUSINESS
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Market survey
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 17
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Trends
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 19
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 20
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 21
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 22
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Niche Market
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Human Capital
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - FEATURE - AUTOMATION
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - 3D X-ray
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 27
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Process
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 29
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 30
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - CNC
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Control
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 33
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 34
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - FCS
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 36
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Filament winding
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Robotics
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - USERS' PLATFORM
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Composites in the world
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 41
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Successful Partners
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 43
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Application
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 45
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 46
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 47
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 48
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - KNOW-HOW
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Preform Control
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 51
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 52
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Thermoplastics
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 54
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 55
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - - Mould
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 57
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 58
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 59
JEC COMPOSITES MAGAZINE - Issue #57 - May 2010 - 60
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