Effects of ultrasound on both electrolytic and electroless nickel depositions

Enabling a high-performance saltwater Al-air battery via ultrasonically driven electrolyte flow

As an emerging battery technology, the Al-air flow battery (AAFB) exhibits high energy density due to the recycling of electrolytes, thus showing great potential as a type of clean and sustainable energy storage system. Conventionally, it employs an external mechanical pump to recycle the electrolyte. In this work, the saltwater AAFB in which the electrolyte is recycled by the ultrasonic capillary effect (rather than a mechanical pump) and the reaction chamber is agitated by ultrasonic vibration, is proposed and investigated. Our numerical simulations show that a travelling ultrasonic wave in the electrolyte flow system causes the capillary flow and agitation. The experimental results show that the percentage increase of the peak power density (relative to that with static electrolyte) can be up to about 7.5 times of that with the electrolyte flow driven by a mechanical pump, under the same electrolyte flow rate and concentration (3.3 ml min^-1 and 3 M NaCl). The optimal peak power density, which can be achieved by optimizing the reaction chamber thickness, electrolyte concentration and ultrasonic vibration velocity, is 43.88 mW cm^-2. This work illustrates that the acoustofluidic method can not only improve the discharge performance of the saltwater AAFB effectively, but also greatly decrease the energy consumption, weight and volume of the electrolyte driving unit of the AAFB. In addition, analyses based on experimental results show that the energy gain of a series/parallel battery system formed by multiple identical cells can be larger than one, if the number of cells in the system is large enough.

Ultrasonic-assisted supercritical-CO2 electrodeposition of Zn-Co film for high-performance corrosion inhibition: A greener approach

The ultrasonic-assisted electrodeposition process significantly improves the mechanical and electrochemical properties. Meanwhile, supercritical fluid technology also enhances the electrodeposition process with increased benefits, such as low surface tension, permeability, high diffusivity, and density, which improves the surface quality through grain refinement. In this study, Zn-Co films were prepared using the ultrasonic-assisted supercritical-CO2 (US-SC-CO2) electrodeposition approach, and its pressure effect on the film was evaluated. The films were also prepared by the conventional and typical supercritical-CO2 (SC-CO2) methods for a comparison study. All the prepared films were characterized by morphological studies, elemental composition, crystal structure orientation, and microhardness tests. Later, the fabricated films were examined by potentiodynamic polarization technique and electrochemical impedance technique (EIS) with 3.5 wt.% NaCl solution for corrosion evaluation. Based on results, Zn-Co film prepared through the US-SC-CO2 process shows a spherical nodule like structure with reduced grain size and significantly enhanced hardness property. In XRD studies, the shift in diffracted peak's position reveals the increased proportion of Co ions. Further, EDX results also confirm the same with the characteristic peaks. Finally, compared to the other methods, the corrosion resistance was more efficient in the US-SC-CO2 process by 73.75%.

The use of non-cavitating coupling fluids for intensifying sonoelectrochemical processes

For the first time, we have investigated the beneficial effects of non-cavitating coupling fluids and their moderate overpressures in enhancing mass-transfer and acoustic energy transfer in a double cell micro-sonoreactor. Silicon and engine oils of different viscosities were used as non-cavitating coupling fluids. A formulated monoethylene glycol (FMG), which is a regular cooling fluid, was also used as reference. It was found that silicon oil yielded a maximum acoustic energy transfer (3.05 W/cm²) from the double jacketed cell to the inner cell volume, at 1 bar of coupling fluid overpressure which was 2.5 times higher than the regular FMG cooling fluid. It was also found that the low viscosity engine oil had a higher acoustic energy value than that of the high viscosity engine oil. In addition, linear sweep voltammograms (LSV) were recorded for the quasi-reversible Fe^2+/Fe³⁺ redox couple (equimolar, 5 × 10^-3 M) on a Pt electrode in order to determine the mass-transport limited current density (j_lim) and the dimensionless Sherwood number (Sh). From the LSV data, a statistical analysis was performed in order to determine the contribution of acoustic cavitation in the current density variation |Δj|_average. It was found that silicon oil at 1 bar exhibited a maximum current density variation, |Δj|_average of ~2 mA/cm² whereas in the absence of overpressure, the high viscosity engine oil led to a maximum |Δj|_average which decreased gradually with increasing coupling fluid overpressure. High viscosity engine oil gave a maximum Sh number even without any overpressure which decreased gradually with increasing overpressure. The Sh number for silicon oil increased with increasing overpressure and reached a maximum at 1 bar of overpressure. For any sonoelectrochemical processes, if the aim is to achieve high mass-transfer and acoustic energy transfer, then silicon oil at 1 bar of overpressure is a suitable candidate to be used as a coupling fluid.

Effect of temperature on ultrasound-assisted electroless nickel-boron plating

Electroless nickel-boron coatings have several advantages over electroplated nickel and electroless nickel-phosphorous: they are harder than both other coatings and, as all electroless coatings, can be applied easily to complex shapes and all substrates, even non conducting ones, contrary to electroplated coatings. Preliminary testing has proved that ultrasound assistance helps improve their properties by increasing the plating rate while conserving the properties of the coating. In this study, the effect of plating temperature on mechanically agitated and ultrasonic assisted electroless nickel-boron deposition was investigated: deposition was performed in two different configurations: one with a classical mechanical agitation at 300 rpm and the other employing ultrasound at a frequency of 35 kHz. In addition, different temperatures in the 80-95 °C range were tested. The increase of plating rate previously observed was confirmed and it was possible to lower slightly plating temperature while conserving plating efficiency, which decreases evaporation of the solution. Morphological, mechanical, corrosion and wear characterization were performed on the coatings, as well as tribocorrosion studies in an alkaline environment (0.1 M NaCl). Ultrasound-assisted coatings presented tribocorrosion behaviour that was similar or better than the standard ones.

Effect of ultrasound on silver electrodeposition: Crystalline structure modification

An attractive possibility for influencing microstructures of electrodeposited coatings, and therefore their properties such as hardness, brightness etc. resides in the use of ultrasound. This method is particularly competitive as it may result in a reduction of chemical use, or even in the complete suppression of chemicals. This paper deals with silver coatings depending strongly on current density, with two main categories identified by X-ray diffraction: one poorly structured and the other following the [110] orientation. It is interesting to note that, while changing from still to mechanically stirred conditions, the value of the current density threshold moves from 2.5mAcm^-2 to 5mAcm^-2. When ultrasound is used (575kHz or 20kHz), this coating microstructure modification threshold occurs at higher current density values when coatings are produced under sonication, while agitation is kept constant. In both cases, the shift is about 15mAcm^-2. It is noteworthy that silver electrodeposits elaborated under 20kHz ultrasound conditions appear to be less oriented than those obtained under high frequency conditions.

Electroless deposition of nickel-boron coatings using low frequency ultrasonic agitation: Effect of ultrasonic frequency on the coatings

The effect of ultrasound on the properties of Nickel-Boron (NiB) coatings was investigated. NiB coatings were fabricated by electroless deposition using either ultrasonic or mechanical agitation. The deposition of Ni occurred in an aqueous bath containing a reducible metal salt (nickel chloride), reducing agent (sodium borohydride), complexing agent (ethylenediamine) and stabilizer (lead tungstate). Due to the instability of the borohydride in acidic, neutral and slightly alkaline media, pH was controlled at pH 12±1 in order to avoid destabilizing the bath. Deposition was performed in three different configurations: one with a classical mechanical agitation at 300rpm and the other two employing ultrasound at a frequency of either 20 or 35kHz. The microstructures of the electroless coatings were characterized by a combination of optical Microscopy and Scanning Electron Microscope (SEM). The chemistry of the coatings was determined by ICP-AES (Inductively Coupled Plasma - Atomic Emission Spectrometry) after dissolution in aqua regia. The mechanical properties of the coatings were established by a combination of roughness measurements, Vickers microhardness and pin-on-disk tribology tests. Lastly, the corrosion properties were analysed by potentiodynamic polarization. The results showed that low frequency ultrasonic agitation could be used to produce coatings from an alkaline NiB bath and that the thickness of coatings obtained could be increased by over 50% compared to those produced using mechanical agitation. Although ultrasonic agitation produced a smoother coating and some alteration of the deposit morphology was observed, the mechanical and corrosion properties were very similar to those found when using mechanical agitation.

Enhancing the adhesion strength of micro electroforming layer by ultrasonic agitation method and the application

Micro electroforming is widely used for fabricating micro metal devices in Micro Electro Mechanism System (MEMS). However, there is the problem of poor adhesion strength between micro electroforming layer and substrate. This dramatically influences the dimensional accuracy of the device. To solve this problem, ultrasonic agitation method is applied during the micro electroforming process. To explore the effect of the ultrasonic agitation on the adhesion strength, micro electroforming experiments were carried out under different ultrasonic power (0W, 100W, 150W, 200W, 250W) and different ultrasonic frequencies (0kHz, 40kHz, 80kHz, 120kHz, 200kHz). The effects of the ultrasonic power and the ultrasonic frequency on the micro electroforming process were investigated by polarization method and alternating current (a.c.) impedance method. The adhesion strength between the electroforming layer and the substrate was measured by scratch test. The compressive stress of the electroforming layer was measured by X-ray Diffraction (XRD) method. The crystallite size of the electroforming layer was measured by Transmission Electron Microscopy (TEM) method. The internal contact surface area of the electroforming layer was measured by cyclic voltammetry (CV) method. The experimental results indicate that the ultrasonic agitation can decrease the polarization overpotential and increase the charge transfer process. Generally, the internal contact surface area is increased and the compressive stress is reduced. And then the adhesion strength is enhanced. Due to the different depolarization effects of the ultrasonic power and the ultrasonic frequency, the effects on strengthening the adhesion strength are different. When the ultrasonic agitation is 200W and 40kHz, the effect on strengthening the adhesion strength is the best. In order to prove the effect which the ultrasonic agitation can improve the adhesion strength of the micro devices, micro pillar arrays were fabricated under ultrasonic agitation (200W, 40kHz). The experimental results show that the residual rate of the micro pillar arrays is increased about 17% by ultrasonic agitation method. This work contributes to fabricating the electroforming layer with large adhesion strength.

Effects of ultrasonic agitation on adhesion strength of micro electroforming Ni layer on Cu substrate

Micro electroforming is an important technology, which is widely used for fabricating micro metal devices in MEMS. The micro metal devices have the problem of poor adhesion strength, which has dramatically influenced the dimensional accuracy of the devices and seriously limited the development of the micro electroforming technology. In order to improve the adhesion strength, ultrasonic agitation method is applied during the micro electroforming process in this paper. To explore the effect of the ultrasonic agitation, micro electroforming experiments were carried out under ultrasonic and ultrasonic-free conditions. The effects of the ultrasonic agitation on the micro electroforming process were investigated by polarization and alternating current (a.c.) impedance methods. The real surface area of the electroforming layer was measured by cyclic voltammetry method. The compressive stress and the crystallite size of the electroforming layer were measured by X-ray Diffraction (XRD) method. The adhesion strength of the electroforming layer was measured by scratch test. The experimental results show that the imposition of the ultrasonic agitation decreases the polarization overpotential and increases the charge transfer process at the electrode-electrolyte interface during the electroforming process. The ultrasonic agitation increases the crystallite size and the real surface area, and reduces the compressive stress. Then the adhesion strength is improved about 47% by the ultrasonic agitation in average. In addition, mechanisms of the ultrasonic agitation improving the adhesion strength are originally explored in this paper. The mechanisms are that the ultrasonic agitation increases the crystallite size, which reduces the compressive stress. The lower the compressive stress is, the larger the adhesion strength is. Furthermore, the ultrasonic agitation increases the real surface area, enhances the mechanical interlocking strength and consequently increases the adhesion strength. This work contributes to fabricating the electroforming layer with large adhesion strength.

Modification of the ultrasound induced activity by the presence of an electrode in a sonoreactor working at two low frequencies (20 and 40 kHz). Part I: Active zone visualization by laser tomography

Sonoelectrochemical experiments differ from sonochemical ones by the introduction of electrodes in the sonicated reaction vessel. The aim of the study is to characterize the changes of the ultrasonic activity induced by the presence of an electrode located in front of the transducer. The scope of our investigations concerns two low frequencies vibration modes: 20 and 40 kHz. For this purpose, two laser visualization techniques have been used. The first part of the study, described in the present paper (part I), deals with the laser tomography technique which provides an accurate picture of the reactor actives zones, related to numerous cavitation events. For each frequency, two parameters were studied: the electrical power supplied to the transducer and the electrode transducer distance. At both frequencies, without electrode, we can observe distinct zones corresponding to cavitation production and stationary waves establishment. When increasing the input power, bubble clouds tend to form a unique cloud near the transducer. In presence of the electrode, bubble cavitation clouds are largely influenced by the obstacle. The second part of the paper (part II) will describe the Particle Image Velocimetry (P.I.V.) technique which allows to measure the velocity vector field in the fluid portion between the horn and the electrode.

Electroplated Nickel Composites with Micron- to Nano-Sized Particles

Electroplated nickel coatings provide ductility, excellent corrosion resistance and good wear resistance, which qualifies them to meet complex demands of engineering, microtechnology and microelectronics. The co-deposition of particles is a promising alternative to deposit layers with adequate microstructure and properties avoiding the rise of residual stress. The incorporation of the sufficient quantity of particles, monodisperse distribution and downsizing to nanometre scale affect the amount of strengthening by dispersion hardening. To avoid agglomeration in the electroplating bath as well as in the layer is a challenge which has been met by simple Watts nickel electrolyte with a minimum of organic additives and adequate bath agitation comprising sonication, i.e. the exposure of the bath to high-frequency sound waves. Well-dispersed hard particles (titanium oxide and silicon carbide) were incorporated in nickel films. The focus was set on the correlation between the gained microstructure of the composites with particles from micron to nanometre scale and the electrochemical and mechanical properties. Corrosion was quantified from polarisation curves and volumetric erosion measurements. Wear resistance was evaluated by scratch energy density studies, oscillating sliding wear testing and cavitation wear testing and compared to indentation hardness results. Sonication and particle downsizing result in matrix grain refinement and dispersion hardening. Incorporation of different particles with respect to different material and size proved to meet different demands. Submicron TiO2 is best for high corrosion resistance, sonicated nickel without particle incorporation is best for high abrasion resistance, nano TiO2 is best for oscillating sliding wear resistance and submicron SiC is best for cavitation wear resistance.