Electrochemical machining (ECM) and especially electrochemical micromachining (μECM) became an attractive area of research due to the fact that this process does not create any defective layer after machining and that there is a growing demand for better surface integrity on different micro applications such as microfluidics systems and stressfree drilled holes in the automotive and aerospace sectors. Electrochemical machining is considered as a non-conventional machining process based on the phenomenon of electrolysis. This process requires maintaining a small gap - the interelectrode gap (IEG) - between the anode (workpiece) and the cathode (tool-electrode) in order to achieve acceptable machining results (i.e. accuracy, high aspect ratio with appropriate material removal rate and efficiency). This work presents the design of a next generation μECM machine for the automotive, aerospace, medical and metrology sectors. It has 3 axes of motion (X, Y and Z) and a spindle allowing the tool-electrode to rotate during machining. The linear slides for each axis use air bearings with linear DC brushless motors and 2nmresolution encoders for ultra-precise motion. The control system is based on the Power PMAC motion controller from Delta Tau. The electrolyte tank is located at the rear of the machine and allows the electrolyte to be changed quickly. A pulse power supply unit (PSU) and a special control algorithm have been implemented. The pulse power supply provides not only ultra-short pulses (50ns), but also plus and minus biases as well as a polarity switching functionality. It fulfils the requirements of tool preparation with reversed ECM on the machine. Moreover, the PSU is equipped with an ultrafast over current protection which prevents the tool-electrode from being damaged in case of short-circuits. Two different process control algorithms were made: one is fuzzy logic based and the other is adapting the feed rate according to the position and time at which short-circuits were detected. The developed machine is capable of drilling micro holes in hard-to-machine materials but also machine micro-styli and micro-needles for the metrology (micro CMM) and medical sectors. This work also presents drilling trials performed with the machine with an orbiting tool. Machining experiments were also carried out using electrolytes made of a combination of HCl and NaNO₃ aqueous solutions. The developed machine was used to fabricate micro tools out of 170μm WC-Co alloy shafts via micro electrochemical turning and drill deep holes via μECM in disks made of 18NiCr6 alloy. Results suggest that this process can be used for industrial applications for hard-to-machine materials. The author also suggests that the developed machine can be used to manufacture micro-probes and micro-tools for metrology and micro-manufacturing purposes.

Biopsy is a standard practice in the diagnosis and treatment of many cancers. Despite its integral role in cancer diagnosis, in some instances, the biopsy tool facilitates metastasis by transferring cancerous cells attached to its exterior into the healthy tissue or the blood circulation during its retraction from the tumor. These few cancer cells can then serve as seeds for the malignant tumor to grow in the healthy tissue. Cauterization using extreme heat or cold can destroy cells in the region and minimize the chance of seeding but this can be an inexact process that increases damage to otherwise healthy tissue and prolongs healing time following a biopsy procedure. In our laboratory, we have developed the concept of a new smart biopsy tool that can reduce the chance of cancer cell dissemination during a biopsy. This tool improves on the conventional biopsy needle by introducing an impedance sensor on the biopsy tool which is housed in a sliding sheath. Due to the significant difference in the electrical conductivity of the tumor and the healthy tissue, the sensor is able to distinguish between the two and locate the exact tumor interface. The protective sheath placed around the instrumented biopsy tool and above the interface isolates the healthy tissue and prevents or at least minimizes the transfer of tumor cells. Delivering an RF dose through the sheath can kill any malignant cells that might be lurking around the interface. This thesis, in particular, will concentrate on the development of the design, fabrication and calibration of the impedance sensor and its integration with the biopsy tool. The impedance sensor essentially consists of conductive electrodes sandwiched between insulating layers. They are built on thin-film polymer, Polyimide, using conventional microfabrication techniques. These sensors are further calibrated to estimate the cell constant. Once calibrated, these probes are used to measure the conductivity of porcine tissues, and in-house prepared agar phantoms. / Master of Science

<p>Turbulent mixing is present in many pulp and paper processes. It is a particularly important factor in the design and improvements of the paper machine headbox, influencing the final paper structure. During this project, experimental methods to quantify the effect of fibers on turbulent suspension flows have been developed, and then used for studying turbulent mixing in fiber suspensions. A technique that uses microprobes to measure passive scalar mixing of salt for the characterization of turbulent fluctuations in a fiber suspension flow has been developed: Conductivity micro-probes have been built and turbulence measurements have been performed in simple jet and wake flows, studying turbulent mixing between the two streams of pulp suspension, of which one has been doped with salt. A relatively new technique to measure fluid velocity non-intrusively in opaque fluids has also been tested. The technique makes use of ultrasonic pulses to obtain velocity information through the Doppler-shift of reflected pulses. The main efforts reported on in the thesis are focused on method design and development as well as method evaluation.</p>

Turbulent mixing is present in many pulp and paper processes. It is a particularly important factor in the design and improvements of the paper machine headbox, influencing the final paper structure. During this project, experimental methods to quantify the effect of fibers on turbulent suspension flows have been developed, and then used for studying turbulent mixing in fiber suspensions. A technique that uses microprobes to measure passive scalar mixing of salt for the characterization of turbulent fluctuations in a fiber suspension flow has been developed: Conductivity micro-probes have been built and turbulence measurements have been performed in simple jet and wake flows, studying turbulent mixing between the two streams of pulp suspension, of which one has been doped with salt. A relatively new technique to measure fluid velocity non-intrusively in opaque fluids has also been tested. The technique makes use of ultrasonic pulses to obtain velocity information through the Doppler-shift of reflected pulses. The main efforts reported on in the thesis are focused on method design and development as well as method evaluation.