PROCESS FOR CHEMICALLY TREATING SURFACES TO INCREASE WETTABILITY

Abstract

Methods and systems are disclosed for chemically treating surfaces of metal parts to increase wettability by contacting the metal parts with a treatment fluid. Metal parts are disclosed that have surfaces free of burrs and with wettability suitable for, as examples, adhesion, bonding, painting, welding, and other processes.

Description

COPYRIGHT

A portion of the disclosure of this patent document may contain material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever

FIELD OF THE INVENTION

The present invention relates to a chemical treatment of metal parts. More particularly, this invention relates to methods and systems for chemically treating surfaces of metal parts to increase the wettability of the metal parts, among other benefits, along with the resulting metal parts from such methods and systems.

BACKGROUND OF THE INVENTION

Various processes used to form parts, and particularly metal parts, leave undesired artifacts on the parts. Such processes include, for example, laser cutting, stamping, mechanical fabrication, milling, and etching. Artifacts left on the parts from such processes include, for example, burrs, pits, and other features. Among other possible issues these artifacts create, they reduce the wettability of the parts. Further, even without undergoing any specific process, various raw materials, and particularly metallic raw materials, have poor wettability.

The present disclosure provides for methods and systems for increasing the wettability of metal parts, along with the resulting products.

All these and other objects of the present invention will be understood through the detailed description of the invention below.

SUMMARY OF THE INVENTION

In one aspect, the present invention is directed to a method for controlling a treatment process. The method includes providing a metal part in a recirculating supply of a fluid to chemically treat the metal part. The fluid has an initial concentration of hydrochloric acid and an initial concentration of ferric chloride in water. The method further includes monitoring a conductivity of the recirculating supply of the fluid to determine a current concentration of the hydrochloric acid. The method further includes maintaining the current concentration of the hydrochloric acid in the recirculating supply of the fluid within a threshold range of the initial concentration of hydrochloric acid by adding more hydrochloric acid to the recirculating supply of the fluid based on the conductivity. The method further includes monitoring a specific gravity of the recirculating supply of the fluid to determine a current specific gravity of the recirculating supply of the fluid. The method further includes maintaining the specific gravity of the recirculating supply of the fluid within a threshold range of a specific gravity set point by adding more water to the recirculating supply of the fluid based on the current specific gravity.

In another aspect, the present invention is directed to a system for chemically treating a surface of a metal part. The system includes a treatment chamber having a recirculating supply of a fluid to chemically treat the surface of the metal part; the fluid including an acid and a salt in water. The system further includes a conductivity probe configured to measure conductivity of the fluid. The system further includes a specific gravity probe configured to measure specific gravity of the fluid. The system further includes a controller configured to adjust the conductivity of the fluid by adding more of the acid to the fluid and configured to adjust the specific gravity of the fluid by adding more of the water to the fluid.

In a further aspect, the present invention is directed to a method for chemically treating a surface of a metal part. The method includes providing the metal part in a treatment chamber. The method further includes contacting the surface of the metal part with a treatment fluid within the treatment chamber to chemically treat the surface of the metal part. The treatment fluid includes about 9.5 to 22.1 percent by volume (vol. %) hydrochloric acid and about 13.5 to 31.5 vol. % ferric chloride in water. The treatment fluid has a specific gravity of about 1.1 to 1.5 grams per cubic centimeter (g/cm²). The method further includes providing the metal part in a rinse chamber after exiting the treatment chamber. The method further includes contacting the surface of the metal part with a rinse fluid in the rinse chamber to rinse the treatment fluid off of the surface of the metal part.

In a further aspect, the present invention is directed to a metal part treated according to the method of preceding paragraph.

In another aspect, the present invention is directed to a metal part having a composition including iron, nickel, copper, or an alloy having one or more of iron, nickel, and copper; and a surface tension of to about 35 to 60 milliNewtons/meter.

Additional aspects of the invention will be apparent to those of ordinary skill in the art in view of the detailed description of various embodiments, which is made with reference to the drawings, a brief description of which is provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described with greater specificity and clarity with reference to the following drawings, in which:

FIG. 1 illustrates a schematic of a system for chemically treating surfaces to increase wettability, according to aspects of the present disclosure.

FIG. 2 illustrates a cross-section of a stamped metal part prior to being chemically treated to increase wettability.

FIG. 3 illustrates a cross-section of the stamped metal part of FIG. 2 after being chemically treated to increase wettability, according to aspects of the present disclosure.

FIG. 4 illustrates a cross-section of an etched metal part prior to being chemically treated to increase wettability.

FIG. 5 illustrates a detailed cross-section of the cross-section of the etched metal part in FIG. 4.

FIG. 6 illustrates a cross-section of the etched metal part in FIG. 4 after being chemically treated to increase wettability, according to aspects of the present disclosure.

FIG. 7 illustrates a detailed cross-section of the cross-section of the etched metal part in FIG. 6, according to aspects of the present disclosure.

FIG. 8 illustrates a surface of a metal part prior to being chemically treated to increase wettability.

FIG. 9 illustrates the surface of the metal part in FIG. 8 after being chemically treated to increase wettability, according to aspects of the present disclosure.

FIG. 10 illustrates a flow diagram for controlling a treatment process, according to aspects of the present disclosure.

FIG. 11 illustrates a flow diagram for chemically treating a surface of a metal part, according to aspects of the present disclosure.

While the invention is susceptible to various modifications and alternative forms, specific embodiments will be shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS

The drawings will herein be described in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. For purposes of the present detailed description, the singular includes the plural and vice versa (unless specifically disclaimed); the words “and” and “or” shall be both conjunctive and disjunctive; the word “all” means “any and all”; the word “any” means “any and all”; and the word “including” means “including without limitation.” Words of approximation, such as “about,” “almost,” “substantially,” “approximately,” and the like, can be used herein to mean “at,” “near,” “nearly at,” “within 3-5% of,” “within acceptable manufacturing tolerances of,” or any logical combination thereof.

The present disclosure involves a chemical treatment process that utilizes fluid dynamics combined with chemical dissolution to produce a surface of a metal part that is burr free with a lower surface tension than the base material. The resulting treated surface provides additive process benefits for adhesion by either chemical, pressure, or heat. The resulting treated surface also provides a benefit to diffusion bonding, painting, welding, and other processes.

The chemical treatment process involves using conductivity to control a hydrochloric acid concentration in a treatment fluid. The treatment fluid also includes ferric chloride. The difference in the conductivity of the hydrochloric acid versus the ferric chloride allows for detectable changes in the conductivity of the fluid being associated with changes in the hydrochloric acid concentration.

FIG. 1 illustrates a schematic of a system 100 for chemically treating surfaces to increase wettability, according to aspects of the present disclosure. Metal parts treated within the system 100 pass through a treatment chamber 102 and then a rinse/drier chamber 104. The treatment chamber 102 includes a recirculating supply of treatment fluid that is sprayed or otherwise contacted onto the metal parts, allowed to fall or flow off, and then collected back in a sump of the treatment chamber 102 for again recirculating through the process. The rinse/drier chamber 104 contacts the metal parts after exiting the treatment chamber 102 with water to rinse off the treatment fluid and then dries the metal parts.

Prior to treating the metal parts, the treatment fluid in the treatment chamber 102 has an initial concentration of hydrochloric acid and an initial concentration of ferric chloride in water. For example, the concentration of the hydrochloric acid in the treatment fluid can be about 9.5 to 22.1 vol. % and the concentration of the ferric chloride in the treatment fluid can be about 13.5 to 31.5 vol. %.

As metal parts are treated in the treatment chamber 102 with the treatment fluid, hydrochloric acid is consumed and various salts are formed based on the composition of metal parts. A controller 106, therefore, monitors the conductivity and the specific gravity of the treatment fluid to maintain conductivity and specific gravity set points within threshold ranges. According to some implementations, the specific gravity is maintained to be about 1.1 to 1.5 g/cm², or more preferably about 1.16 to 1.42 g/cm², or even more preferably about 1.38 to 1.42 g/cm². The system 100 includes a conductivity measurement loop 108 with a conductivity probe 110 that measures the conductivity of the treatment fluid. The system 100 also includes a specific gravity measurement loop 112 with a specific gravity probe 114 that measures the specific gravity of the treatment fluid. Treatment fluid passes through the loops 108 and 112 for measurement of the conductivity and the specific gravity, respectively. Based on the measurements, the controller 106 adds more hydrochloric acid (based on the conductivity) and/or more water (based on the specific gravity) to maintain the set points within the threshold ranges.

According to some implementations, the system 100 includes a temperature (or heater) controller 116 that controls the temperature of the treatment fluid. A thermocouple 118 measures the temperature of the treatment fluid in the treatment chamber 102. In response to the measured temperature, the controller 116 controls a heater 120 and/or a cooling loop 122, with an associated chiller 124, to control the temperature of the treatment fluid to within a threshold range of a set point. According to some implementations, the set point is about 125° F. (52° C.) and the range is about 120 to 140° F. (about 49 to 60° C.).

FIG. 2 illustrates a cross-section of a stamped metal part 200 prior to being chemically treated to increase wettability. As illustrated, the stamped metal part 200 part has a thickness of 9.696 thousands of an inch (mils) (0.2462 millimeters (mm)). Because the stamped metal part 200 was formed by a stamping process, the stamped metal part 200 has a burr 202 at the top-right corner. The burr 202 has a height of 0.988 mil (0.0251 mm). Also because the stamped metal part 200 was formed by a stamping process, the stamped metal part 200 has a rounded edge 204 at the bottom-right corner.

FIG. 3 illustrates a cross-section of the stamped metal part 200 of FIG. 2 after being chemically treated to increase wettability, i.e., a treated metal part 300. Material has been removed from each surface of the stamped metal part 200 by the chemical treatment. Thus, the thickness of the treated metal part 300 is now 8.495 mils (0.2158 mm) because material has been removed from the top surface and the bottom surface. In other words, about 4.248 mils (0.1079 mm) of material has been taken off of each of the top surface and the bottom surface of the stamped metal part 200. The burr illustrated in the top-right corner of FIG. 2 has also be removed by the chemical treatment process, causing the top-right corner 302 in FIG. 3 to now have a rounded profile. The chemical treatment process has also removed material from the bottom-right corner of FIG. 2, causing the bottom-right corner in FIG. 3 to have a more curved profile 304 as compared to what is illustrated in FIG. 2.

FIG. 4 illustrates a cross-section of an etched metal part 400 prior to being chemically treated to increase wettability, according to aspects of the present disclosure. FIG. 5 illustrates a detailed view of the cross-section of the etched metal part 400 in FIG. 4, according to aspects of the present disclosure. The etched metal part 400 can be formed as a result of various different etching processes. As can be seen in FIG. 4, and even more so in FIG. 5, the surfaces 402 and 404 of the etched metal part 400 include pits 406 caused by the etching process used to form the metal part.

FIG. 6 illustrates a cross-section of the etched metal part 400 in FIG. 4 after being chemically treated to increase wettability, i.e., a treated metal part 600, according to aspects of the present disclosure. FIG. 7 illustrates a detailed view of the cross-section of the treated metal part 600 in FIG. 6, according to aspects of the present disclosure. As can be seen in FIG. 6, and even more so in FIG. 7, the surfaces 602 and 604 of the treated metal part 600 are now smoother because the chemical treatment process has removed the pitting.

The removal of material of the metal parts illustrated in FIGS. 3, 6, and 7 increases the wettability of the metal part. The increased wettability increases the performance of the metal parts for additive process, such as electroplating and painting, and the application of thermal and pressure sensitive adhesives. The increased wettability also enhances the surfaces for diffusion bonding and welding, along with the chemical performance in fuel cell applications. The chemical treatment process also reduces chemical surface tension on the metal parts and improves chemical control of solution.

FIG. 8 illustrates a surface 800 of a metal part prior to being chemically treated to increase wettability, according to aspects of the present disclosure. Specifically, FIG. 8 illustrates the ink 802 from a 38 Dyne pen. The non-contiguous ink 802 from the 38 Dyne pen indicates that the wettability of the surface of the metal part is less than 38 Dyne/cm (35 milliNewtons/meter (mN/m)).

FIG. 9 illustrates the surface of the metal part 800 in FIG. 8 after being chemically treated to increase wettability, i.e., a treated surface 900, according to aspects of the present disclosure. The same 38 Dyne pen was used to show the increase in the wettability. More specifically, the contiguous ink 902 from the 38 Dyne pen in FIG. 9 indicates that the wettability of the surface of the metal part is equal to or greater than 38 Dyne/cm (35 mN/m).

FIG. 10 illustrates a flow diagram for a process 1000 of chemically treating surfaces to increase wettability, according to aspects of the present disclosure. At step 1002, one or more metal parts are provided in a recirculating supply of a fluid to chemically treat the one or more metal parts, such as in the treatment fluid within the system 100 discussed above. The fluid has an initial concentration of hydrochloric acid and an initial concentration of ferric chloride in water. According to some implementations, the initial concentration of the hydrochloric acid is about 9.5 to 22.1 vol. % According to some implementations, the initial concentration of the ferric chloride is 13.5 to 31.5 vol. %. The specific concentration of the fluid can be set points within these ranges, where the set points depend on the composition of the one or more metal parts being chemically treated.

The one or more metal parts can be provided in the recirculating supply of the fluid for various amounts of time depending on how much chemical treatment the metal parts need. According to some implementations, the amounts of time can be about 30 seconds to about three minutes, such as about 45 seconds. For 45 seconds, the process removes a thickness of about 0.01 mm of material from each surface of the metal parts for a total thickness of about 0.02 mm of removed material.

At step 1004, the conductivity of the recirculating supply of the fluid is monitored to determine a current concentration of the hydrochloric acid. The conductivity can be monitored with one or more conductivity monitors.

At step 1006, the current concentration of the hydrochloric acid in the recirculating supply of the fluid is maintained within a threshold range of the initial concentration of hydrochloric acid by adding more hydrochloric acid to the recirculating supply of the fluid based on the conductivity. The concentration of the hydrochloric acid added to the fluid can be any concentration that is higher than the concentration of hydrochloric acid currently in the fluid. According to some implementations, the concentration of the hydrochloric acid added to the fluid can be, for example, 30 to 70 vol. %, such as 30 vol. %, 35 vol. %, 40 vol. %, 45 vol. %, 70 vol. %, and any value in-between.

At step 1008, the specific gravity of the recirculating supply of the fluid is monitored to determine a current specific gravity of the recirculating supply of the fluid. The specific gravity can be monitored with one or more conductivity monitors.

At step 1010, the specific gravity of the recirculating supply of the fluid is maintained within a threshold range of a specific gravity set point by adding more water to the recirculating supply of the fluid based on the current specific gravity. According to some implementations, the specific gravity of the fluid is maintained at 1.1 to 1.5 g/cm², or more preferably about 1.16 to 1.42 g/cm², or even more preferably about 1.38 to 1.42 g/cm². In some preferred implementations, the specific gravity is maintained at about 1.395 g/cm².

According to some implementations, monitoring the conductivity and maintaining the current concentration of the hydrochloric acid occur for a first period of time to ensure that the current concentration of the hydrochloric acid is at steady-state prior to providing the one or more metal parts in the recirculating supply of the fluid. For example, the first period of time can be two minutes. However, the first period can be any length of time required for current concentration to reach steady-state.

According to some implementations, monitoring the specific gravity and maintaining specific gravity in the recirculating supply of the fluid occur for a second period of time to ensure that the current concentration of the hydrochloric acid is at steady-state after the monitoring the conductivity and the maintaining the current concentration of the hydrochloric acid and prior to the providing the one or more metal parts in the recirculating supply of the fluid. For example, the second period of time can be two minutes. However, the second period can be any length of time required for current concentration to reach steady-state.

FIG. 11 illustrates a flow diagram of a process 1100 for chemically treating a surface of a metal part, according to aspects of the present disclosure.

At step 1102, the metal part is provided in a treatment chamber, such as the treatment chamber 102 in FIG. 1. For example, the metal part can be on a conveyor belt that brings the metal part into the treatment chamber.

At step 1104, the surface of the metal part is contacted with a treatment fluid within the treatment chamber to chemically treat the surface of the metal part. The treatment fluid includes about 9.5 to 22.1 vol. % hydrochloric acid and about 13.5 to 31.5 vol. % ferric chloride in water. The treatment fluid has a specific gravity of about 1.1 to 1.5 g/cm². The temperature of the treatment fluid can be about 49-60° C., such as about 52° C. The specific gravity of the treatment fluid is, in preferred implementations, 1.395 g/cm². The contact time can be about 30 to 60 seconds, such as 45 seconds.

At step 1106, the metal part is provided in a rinse chamber after exiting the treatment chamber. For example, the conveyor belt of step 1102 continues after the treatment chamber to a rinse/drier chamber.

At step 1108, the surface of the metal part is contacted with a rinse fluid in the rinse chamber to rinse the treatment fluid off of the surface of the metal part. The rinse fluid can be any fluid that is non-reactive with the metal part over an amount of time required to rinse and dry the metal part. For example, the rinse fluid can be water, such as tap water or de-ionized water.

The metal parts treated by the process 1000 can be any metal part with a composition of iron, nickel, copper, or an alloy having one or more of iron, nickel, and copper. According to some implementations, the metal part can be an alloy containing about 39 to 41 weight percent (wt. %) cobalt, about 19 to 21 wt. % chromium, about 14 to 16 wt. % nickel, about 11.3 to 20.5 wt. % iron, about 6 to 8 wt. % molybdenum, about 1.5 to 2.5 wt. % manganese, and no more than 0.15 wt. % carbon. The metal parts can have various different shapes and sizes, such as lengths of about 25 to 600 mm, widths of about 25 to 600 mm, and thicknesses of about 0.05 to 6.3 mm. However, these ranges are merely exemplary and are not meant to be limiting. The metal parts can have any shape and size depending on the size and configuration of the treatment chamber (e.g., treatment chamber 102 in FIG. 1) in which the process occurs.

These embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. Moreover, the present concepts expressly include any and all combinations and subcombinations of the preceding elements and aspects.

Claims

1. A method for controlling a treatment process, the method comprising: providing a metal part in a recirculating supply of a fluid to chemically treat the metal part, the fluid having an initial concentration of hydrochloric acid and an initial concentration of ferric chloride in water;monitoring a conductivity of the recirculating supply of the fluid to determine a current concentration of the hydrochloric acid;maintaining the current concentration of the hydrochloric acid in the recirculating supply of the fluid within a threshold range of the initial concentration of hydrochloric acid by adding more hydrochloric acid to the recirculating supply of the fluid based on the conductivity;monitoring a specific gravity of the recirculating supply of the fluid to determine a current specific gravity of the recirculating supply of the fluid; andmaintaining the specific gravity of the recirculating supply of the fluid within a threshold range of a specific gravity set point by adding more water to the recirculating supply of the fluid based on the current specific gravity.

2. The method of claim 1, wherein the monitoring the conductivity and the maintaining the current concentration of the hydrochloric acid occur for a first period of time to ensure that the current concentration of the hydrochloric acid is at steady-state prior to providing the metal part in the recirculating supply of the fluid.

3. The method of claim 2, wherein the monitoring the specific gravity and the maintaining the specific gravity in the recirculating supply of the fluid occur for a second period of time to ensure that the current concentration of the hydrochloric acid is at steady-state after the monitoring the conductivity and the maintaining the current concentration of the hydrochloric acid and prior to the providing the metal part in the recirculating supply of the fluid.

4. The method of claim 1, wherein the initial concentration of hydrochloric acid in the fluid is a first set point based on a composition of the metal part within a range of 9.5 to 22.1 vol. %, and the initial concentration of ferric chloride in the fluid is a second set point based on the composition of the metal part within a range of 13.5 to 31.5 vol. %, the method further comprising maintaining a temperature of the recirculating supply of the fluid at about 52° C.

5. The method of claim 1, wherein a composition of the metal part includes iron, nickel, copper, or an alloy having one or more of iron, nickel, and copper, and the metal part is provided in the recirculating supply of the fluid for about 45 seconds to remove about 0.01 mm of material from each surface of the metal part.

6. The method of claim 1, wherein the providing the metal part in the recirculating supply of the fluid includes spraying the recirculating supply of the fluid on the metal part as the metal part passes through a treatment chamber.

7. A system for chemically treating a surface of a metal part, the system comprising a treatment chamber having a recirculating supply of a fluid to chemically treat the surface of the metal part, the fluid including an acid and a salt in water;a conductivity probe configured to measure conductivity of the fluid;a specific gravity probe configured to measure specific gravity of the fluid; anda controller configured to adjust the conductivity of the fluid by adding more of the acid to the fluid and configured to adjust the specific gravity of the fluid by adding more of the water to the fluid.

8. The system of claim 7, further comprising: a conductivity measurement loop configured to withdraw a portion of the fluid from the treatment chamber, for measurement of the conductivity, and deposit the portion of the fluid back into the treatment chamber, after the measurement of the conductivity,wherein the conductivity probe is within the conductivity measurement loop.

9. The system of claim 7, further comprising: a specific gravity measurement loop configured to withdraw a portion of the fluid from the treatment chamber, for measurement of the specific gravity, and deposit the portion of the fluid back into the treatment chamber, after the measurement of the specific gravity,wherein the specific gravity probe is within the specific gravity measurement loop.

10. The system of claim 7, further comprising: a heater, a chiller, or a combination thereof to maintain a temperature of the recirculating supply of the fluid.

11. The system of claim 10, wherein the temperature of the fluid is maintained at about 52° C.

12. The system of claim 7, wherein the acid is hydrochloric acid at a concentration of 9.5 to 22.1 vol. % and the salt is ferric chloride at a concentration of 13.5 to 31.5 vol. %.

13. The system of claim 12, wherein the specific gravity of the fluid is about 1.395 g/cm2.

14. A method for chemically treating a surface of a metal part, the method comprising: providing the metal part in a treatment chamber;contacting the surface of the metal part with a treatment fluid within the treatment chamber to chemically treat the surface of the metal part, the treatment fluid including about 9.5 to 22.1 vol. % hydrochloric acid and about 13.5 to 31.5 vol. % ferric chloride in water, and the treatment fluid having a specific gravity of about 1.1 to 1.5 g/cm2;providing the metal part in a rinse chamber after exiting the treatment chamber; andcontacting the surface of the metal part with a rinse fluid in the rinse chamber to rinse the treatment fluid off of the surface of the metal part.

15. The method of claim 14, wherein the temperature of the treatment fluid is about 52° C. and the specific gravity of the treatment fluid is 1.395 g/cm2.

16. The method of claim 14, wherein the metal part is contacted with the treatment fluid for about 45 seconds.

17. The method of claim 16, wherein about 0.01 mm of material is removed from the surface of the metal part from contacting the surface with the treatment fluid.

18. The method of claim 14, wherein a composition of the metal part includes iron, nickel, copper, or an alloy having one or more of iron, nickel, and copper.

19. The method of claim 14, wherein contacting the surface of the metal part with the treatment fluid within the treatment chamber includes spraying the treatment fluid on the metal part as the metal part passes through the treatment chamber on a conveyor belt.

20. A metal part treated according to the method of claim 14.

21. The metal part of claim 20, wherein a surface tension of the metal part is about 35 to 60 milliNewtons/meter.

22. The metal part of claim 20, wherein the metal part has a composition including iron, nickel, copper, or an alloy having one or more of iron, nickel, and copper.

23. The metal part of claim 20, wherein the metal part has a thickness of about 0.12 to 6.3 mm.

24. The metal part of claim 20, wherein the metal part is a laser cut metal part, a stamped metal part, a mechanically fabricated metal part, a milled metal part, or an etched metal part, and the metal part is free of surface pits and metal burrs.

25. The metal part of claim 24, wherein the metal part is the stamped metal part and includes burrs prior to being treated and is free of the burrs after being treated.

26. The metal part of claim 20, wherein the metal part is treated for about 45 seconds.

27. A metal part comprising: a composition including iron, nickel, copper, or an alloy having one or more of iron, nickel, and copper; anda surface tension of to about 35 to 60 milliNewtons/meter.

28. The metal part of claim 27, further comprising: a thickness of about 0.05 to 6.3 mm.

29. The metal part of claim 27, wherein the metal part is a laser cut metal part, a stamped metal part, a mechanically fabricated metal part, a milled metal part, or an etched metal part.

30. The metal part of claim 29, wherein the stamped metal part is free of burrs.