Modeling of Industrial Electroplating Processes with Comsol Multiphysics in Order to Optimize Treatment of Complex Parts

Abstract

Electroplating processes are widely used on several aeronautical applications to confer functional properties (electrical conductivity, tribological, anti-corrosion). In this industrial context, it is possible to keep the desired properties by respecting specifications such as thicknesses and coating composition for alloys. However, it is well-known that phenomena intrinsic to electrochemical processes create heterogeneities, especially on complex geometries like landing gears. Industrially, the treatment of these disparities is part of the know-how of the workshops, and they are balanced by complex auxiliary tools in order to obtain a more uniform local current densities distribution, and therefore coating thickness. The development of these specific anode shapes is time-consuming and depends strongly of an empirical know-how. The numerical simulation of electrochemical processes is developed at Safran Tech in collaboration with Institute Utinam to optimize the development of plating tools at industrial scale with ComsolÒ Multiphysic software. The global objective is to improve the reliability of the existing systems, and moreover to enhance the innovation by facilitating new coatings integration. This is crucial in the context of tightening of environmental REACH regulations, such as the substitution of cadmium by zinc-nickel. Modeling industrial electroplating processes by a secondary current distribution model is evaluated in terms of thickness prediction by a comparison with experimental results at a laboratory scale pilot. It has been emphasized that the main limitation are due to the failure to take full account of mass transport induced by convection. The study also participate to the development of good practice for auxiliary tools design, and the simulation demonstrate invaluable assistance in industrial operations. Figure 1

3D Printed Lithium-Metal Full Batteries Based on a High-Performance Three-Dimensional Anode Current Collector

“…These results are in accordance with the theory of lightning rod, indicating that the charge density on the surface of the conductor increases with the curvature of the conductor . Subsequently, as shown in Figure c,f, the evolution of the morphology of lithium during the deposition was simulated by combining the deformation geometry function in COMSOL with the two current densities mentioned above . Lithium is preferentially deposited at 25 mA cm –2 , a high current density, on top of the 3D copper mesh like a mushroom head (Figure c).…”

“…48 Subsequently, as shown in Figure 3c,f, the evolution of the morphology of lithium during the deposition was simulated by combining the deformation geometry function in COMSOL with the two current densities mentioned above. 49 Lithium is preferentially deposited at 25 mA cm −2 , a high current density, on top of the 3D copper mesh like a mushroom head (Figure 3c). Figure 3d schematically shows the deposition result.…”