Electroforming Copper Feedhorns Using Aluminum Mandrels

Chemistry, Technology
[caption id="attachment_24084" align="alignright" width="480"] Copper electroforming bath, with growing electroforms and bagged anodes. Pump and continuous bath filtration are essential, though they are not shown for clarity.[/caption] The electroplating laboratory technician may be asked to grow a metal object from scratch, rather than merely plate an existing part. The result, before final external machining, is called an electroform. Electroforming involves much more than merely plating a long time. Critical issues need to be addressed to ensure success. While electroforming involves science, it is truly an art. Definitions and Basics [caption id="attachment_24085" align="alignleft" width="300"] A microwave feedhorn is similar to an old-fashioned ear trumpet. Image National Archives.[/caption] Microwaves are electromagnetic waves with a wavelength in the range of 0.001–0.3 meters. When creating a microwave feedhorn via electroforming, the scientist will grow…
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