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Controlling coating thickness distribution for a complex geometry with the help of simulation
Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
CCM Compressor & Components Mfg GmbH, Thalheimer Str 7, D-09125 Chemnitz, Germany..
Jönköping University, School of Engineering, JTH, Materials and Manufacturing.ORCID iD: 0000-0003-2924-137X
2024 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 134, p. 3703-3717Article in journal (Refereed) Published
Abstract [en]

This paper aims to develop a proper and valid simulation model for electroplating complex geometries. Since many variables influence the quality of the deposited coating and its thickness distribution, it is challenging to conduct efficient research only through experiments. In contrast, simulation can be an efficient way to optimize the electroplating experiments. Despite its potential, simulation has seen limited commercial use in the electroplating industry due to its inherent complexity and difficulty in achieving accurate precision for intricate geometries. The present study addresses the aspects that can enhance the electroplating simulation's accuracy, which has been typically overlooked in the literature, such as the effect of current efficiency and its dependency on the current density, the input data for the electrode kinetics, the surface topology changes, and the differences between 2 and 3D simulations. The simulation model was validated by experimental results related to the coating thickness of Ni plating on a T-joint geometry. The results showed good agreement with the experimental ones, confirming the model's ability to precisely predict the coating thickness and distribution and promote its broader utilization in the industry. Finally, the developed model was used to determine the optimal current density regime for achieving uniform coating thickness distribution on a T-joint sample.

Place, publisher, year, edition, pages
Springer, 2024. Vol. 134, p. 3703-3717
Keywords [en]
Electroplating, Simulation, Moving boundary, Coating thickness, Level set
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:hj:diva-66220DOI: 10.1007/s00170-024-14337-6ISI: 001308090300005Scopus ID: 2-s2.0-85203148374Local ID: HOA;;972125OAI: oai:DiVA.org:hj-66220DiVA, id: diva2:1898134
Funder
Vinnova, 2021–01904Available from: 2024-09-16 Created: 2024-09-16 Last updated: 2025-10-13Bibliographically approved

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Ahmadkhaniha, DonyaSieber, MaximilianZanella, Caterina

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