Simulations of fluid flow, mass transport and current distribution in a parallel plate flow cell during nickel electrodeposition

Electrodeposition model with dynamic ion diffusion coefficients for predicting void defects in electroformed microcolumn arrays

Due to the confined mass transfer capability in microchannels, void defects are easily formed in electroformed microcolumn arrays with a high depth/width ratio, which seriously affects the life and performance of micro-devices. The width of the microchannel constantly decreases during electrodeposition, which further deteriorates the mass transfer capability inside the microchannel at the cathode. In the traditional micro-electroforming simulation model, the change of the ion diffusion coefficient is always ignored, making it difficult to accurately predict the size of void defects prior to electroforming experiments. In this study, nickel ion diffusion coefficients in microchannels are tested based on the electrochemical experiments. The measured diffusion coefficients decrease from 4.74 × 10^-9 to 1.27 × 10^-9 m² s^-1, corresponding to microchannels with a width from 120 to 24 μm. The simulation models of both constant and dynamic diffusion coefficients are established, and the corresponding simulation results are compared with the void defects obtained using micro-electroforming experiments. The results show that when the cathode current densities are 1, 2 and 4 A dm^-2, the size of void defects obtained with the dynamic diffusion coefficient model is closer to the experimental results. In the dynamic diffusion coefficient model, the local current density and ion concentration distribution proves to be more inhomogeneous, leading to a big difference in the deposition rate of nickel between the bottom and the opening of a microchannel, and consequently a larger void defect in the electroformed microcolumn arrays. In brief, the ion diffusion coefficient inside microchannels with a different width is tested experimentally, which provides a reference for developing reliable micro-electroforming simulation models.

Numerical and Experimental Investigation of the Effect of Current Density on the Anomalous Codeposition of Ternary Fe-Co-Ni Alloy Coatings

Gradient-structured ternary Fe-Co-Ni alloy coatings electrodeposited on steel substrates at various current densities from chloride baths were numerically and experimentally investigated. The electrodeposition process, considering hydrogen evolution and hydrolysis reaction, was modelled using the finite element method (FEM) and was based on the tertiary current distribution. The experimentally tested coating thickness and elemental contents were used to verify the simulation model. Although there was a deviation between the simulation and experiments, the numerical model was still able to predict the variation trend of the coating thickness and elemental contents. The influence of the current density on the coating characterization was experimentally studied. Due to hydrogen evolution, the coating surface exhibited microcracks. The crack density on the coating surface appeared smaller with increasing applied current density. The XRD patterns showed that the deposited coatings consisted of solid-solution phases α-Fe and γ (Fe, Ni) and the metallic compound Co₃Fe₇; the current density in the present studied range had a small influence on the phase composition. The grain sizes on the coating surface varied from 15 nm to 20 nm. The microhardness of the deposited coatings ranged from 625 HV to 655 HV. Meanwhile, the average microhardness increased slightly as the current density increased from 5 A/dm² to 10 A/dm² and then decreased as the current density further increased. Finally, the degree of anomaly along with the metal ion and hydrogen atom concentrations in the vicinity of the cathodic surface were calculated to investigate the anomalous codeposition behaviour.

Modelling the Scaling-Up of the Nickel Electroforming Process

Electroforming is increasingly gaining recognition as a promising and sustainable additive manufacturing process of the “Industry 4.0” era. Numerous important laboratory-scale studies try to shed light onto the pressing question as to which are the best industry approaches to be followed towards the process’s optimisation. One of the most common laboratory-scale apparatus to gather electrochemical data is the rotating disk electrode (RDE). However, for electroforming to be successfully optimised and efficiently applied in industry, systematic scale up studies need to be conducted. Nowadays, well-informed simulations can provide a much-desired insight into the novelties and limits of the process, and therefore, scaling up modelling studies are of essence. Targeted investigations on how the size and geometry of an electroforming reactor can affect the final product could lead to process optimisation through simple modifications of the setup itself, allowing immediate time- and cost-effective adjustments within existing production lines. This means that the accuracy of results that any scaled up model provides, if compared to a successful, smaller scale version of itself, needs to be investigated. In this work a 3-D electrodeposition model of an RDE was used to conduct geometry and model sensitivity studies using a commercial software as is often done in industry. As a next step, a 3-D model of an industrial-scale electroforming reactor, which was 90 times larger in electrolyte volume compared to the RDE, was developed to compare, and identify the key model parameters during scale up. The model results were validated against experimental data collected in the laboratory for both cases to assess model validity.