Metal bellows are produced by rolling, welding, hydroforming and electroforming, but only electroformed bellows feature uniform metal composition and isotropic material properties, unaffected by the heat of welding or the strains of cold working.
In bellows electroforming, metal is electroplated onto a conductive substrate of the desired configuration, called a mandrel. Mandrels for bellows are often machined out of Aluminum, which allows them to be chemically dissolved after electroforming, leaving behind a stress-free bellows, as shown in the illustration on the right.
Electroformed Nickel bellows have been in production since the middle of the last century. Their manufacture required modifications to the Nickel plating solution to assure bellows' strength and elasticity. But the modified chemistry compromised the metal's high temperature properties, limiting the operating range of Nickel bellows to 350°F. Such bellows, therefore, could not be brazed or welded. Their corrosion resistance was also affected. Additionally, thin Nickel bellows (<50 micron/.002") were porous, and could not be used in applications, requiring hermetic components. To overcome this difficulty, a Copper lamina was plated halfway through the Nickel wall, 'plugging' the pores.
Since its inception, NiCoForm's goal was an electroformable material free from the limitations of electrodeposited Nickel. This lead to the development of NiColoy®, a trademarked family of Nickel-based engineering electrodeposits. Possessing improved mechanical and thermal properties, these alloys could be used over a wider temperature range (cryogenic up to 600º F), and withstand higher stresses without permanent deformation. NiColoy® bellows are electroformed with a uniform wall thickness. When properly designed, they can be soldered, welded and brazed. Freedom from stress assures the material's reliable performance in extension, compression, bending and rotation. Non-porous and corrosion resistant, NiColoy® bellows require no Copper lamina to be Helium leakproof.
Today, electroformed NiColoy® bellows successfully replace their electrodeposited Nickel counterparts across the board, and are the only choice where the improved performance and greater consistency of NiColoy® are essential.
NiCoForm's advanced mass-electroforming technology produces bellows with otherwise unattainable part-to-part consistency and reliable performance in extension, compression, bending and rotation
NiColoy® bellows can be produced with walls as thin as 0.0004” (10 µm), and diameters as low as 0.03” (0.75 mm) - much smaller than possible with alternate methods - making them ideal for precision sensing applications. On the opposite end of the spectrum lie electroformed bellows 10” (250 mm) in diameter and 25” (625 mm) long
When specified, Copper, Silver, Gold, Rhodium and other coatings further increase the bellows' corrosion resistance and improve their contact performance in electronics
Leak testing of bellows is performed by helium mass spectrometry up to 10-9 ccHe/sec
NiColoy® bellows can be hermetically attached to mating components by welding, brazing, soldering, electrojoiningand the use of adhesives
A Partial List of Electroformed Bellows Applications
Accumulators
Actuators
Compensators
Couplings
Bladder
Diaphragm
Piston
Pressure
Temperature
Alignment
Volume
Flexible Shaft
Low Inertia
Torque
Expansion Joints
Seals
Sensors
Miscellaneous
Pressure
Thermal
Axial
Hermetic
Mechanical
High Sensitivity
Pressure
Temperature
Sealed Contacts
Dynamic Pump Housings
Whether you are supporting an existing product or develop a new application, our experts can help you design, optimize, prototype and manufacture your bellows in a timely, efficient and cost-effective fashion.
Please enter your project parameters into the form here, so we can assist with your bellows design.
At NiCoForm, there is no need to choose from a standard line of components - we custom engineer bellows to your specifications
Bellows Electroforming Steps (X-section)
Small Electroformed Bellows
Bellows Assembly
Miniature Bellows and Cold Shields
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NiCoForm, Inc. 72 Cascade Dr. Rochester, NY 14614 toll free : 877-NICOLOY (642-6569) | phone : 585-454-5530 | fax : 585-454-5167 | | sitemap
