(Invited) Transition from Coupon Observation to Part Processing and the Challenges in Between

Faraday Technology Inc. is a research, development and engineering firm developing electrochemical innovations based has pulse/pulse reverse electrolytic principles [1]. With that founding basis Faraday has been able to bridge the gap between academic understanding and small scale demonstration to commercialization of practical components over 27 years of operation. This presentation will discuss some of the observations and challenges that have come up as a result of moving from exemplar “coupon scale” materials toward practical part shapes and geometries. Furthermore, we will discuss a range of applications and materials including but not limited to Cu/Cr single metal plating, CoMn/NiCr alloy plating, included deposit formations with CrAlY or WC particles, electropolishing of additively manufactured components, and Nb cavity polishing. Within each of these very distinct processes and applications we will try to identify similarities and differences in the observed challenges and ways that many could be overcome either by electrochemical engineering, process developments, or program planning. References: J. Taylor “Adventures in Pulse/Pulse Reverse Electrolytic Processes: Explorations and Applications in Surface Finishing” J. Applied Surface Finsihing, 3(4), 178-189 (2008).