5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December

12th–14th, 2014, IIT

Guwahati, Assam, India

A STUDY OF ELECTROPLATING PROCESS THROUGH EXPERIMENT AND SIMULATION

Abhijeet Selhi1, Sai Nikhil2

1
Mechanical Engineering student,
BITS,Pilani - K.K.Birla Goa Campus, 403726, [email protected]
2
Mechanical Engineering student,
BITS,Pilani-K.K.BirlaGoa Campus, 403726, [email protected]

Abstract
Electroplating is an economically important process, often used to reduce corrosion and improve the appearance of
objects. During electroplating a thin layer of desirable metal is deposited onto another object. The effect of some
process parameters on the weight and thickness of zinc deposited on mild steel in a typical electroplating process is
reported. This study indicates that the weight and thickness of zinc deposited on mild steel during the process is
affected by plating time, voltage distribution, distance between electrodes and their positioning. It also validates the
experimental results by simulation using COMSOL software. Simulation of electroplating acts as a prototype for the
process wherein one can predict the outcome before the actual plating. This can help to estimate the time required
for obtaining particular quantity of metal deposited(weight and thickness) and vice versa. Results led to the
conclusion that as experimental time increases the coating thickness increases. Also, increase of distance of work-
piece from center leads to decrease in coating thickness which is evident from microscopic images of surface
coatings.

1. Introduction Krishaet al (2005) [1] tells us that properties of

excluded zinc coatings depend on their structure, the
Electroplating uses electric current and
type of bath and its composition.
electrochemical reaction for making metal coatings.
Coatings may be formed by copper, nickel, chromium,
2. Experimentation
zinc, tin, cadmium, silver, gold and others.
2.1 Pretreatment for electroplating
Electroplating is one of the most difficult surface
This experiment used cylindrical and plate work-
adjustment technologies for pre-treatment products. It is
pieces made up of MS of which surface was hit by
clear, because the transmission of metal ion from
corrosion and grease. Pretreatment beforeelectroplating
solution on the surface of cathode and its incorporation
is very important because the inclusion of metal ion
to the crystal grid require perfect contact of phases.
from solution to the crystallattice requires perfect
Selection of technology depends on the type of
contact phases.
electroplating products and bath, electroplating
Mechanical pretreatment: Abrasive paper was
technique, condition of surface and technical equipment
used for the removal of hard impurities and asperities
of electroplating plant.
caused by drilling. A part of the rust was removed by
Technology of electroplating has been known for a
simple motions in variousdirections. Rinse-This
long time, and it has been used for preparation of
operation was included between each treatment and also
coating in models of complex form (galvanoplatics),
as a finish treatment. In the beginning, the rinse
and for thin coating on subjects for the purpose of
wasdone bysprinklingwithdistilled water, butthis
protecting metals mostly from corrosion (galvanization)
method left marks after drying.
as mentioned by Budmanet al.(1998) [3].
Chemical pretreatment: Zn coated work-pieces
Electrochemical processes are of major importance for
were immersed in Hydrochloric Acid for removal of
this branch. Zinc coats are most often used as an
stains and impurities.
intermediate layer for protective or decorative
2.2 Experimental Information
electroplating in nickeling and silvering, either as a
Container used has volume of 400L.Rectifier input
protective layer in cementation in galvanoplastics, or as
was 440V and rectifier output was 0-30V (DC), 0-300A
a decorative coat. In last case, excluded coating must be
.Initial weights of the work pieces and perpendicular
protected from the corrosion effects of the outside
distance between electrodes (work-pieces) were noted.
atmosphere by a suitable coat. The most often used zinc
Electroplating was performed for cylindrical and plate
baths are chloride solution and sulphate solution.Abou-

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A STUDY OF ELECTROPLATING PROCESS THROUGH EXPERIMENT AND SIMULATION

work-pieces placed at center and offset (about 8.5 cm then becomes U = KJn where K is the coefficient of
from center) for 10 minutes and 20 minutes. proportionality, and Jn is the normal current density.
Electroplated work-pieces were washed with water and Inthis model, K=10-11 m3/As.The part of the electrode
dipped in Nitric Acid and later dried to neutralize the and electrolyte that model includes is about 0.2m
acidic zinc on the surface and to give a shiny surface. wideand the distance between the cathodes is 0.4m.
Difference in pre-coated and post-coated weights of
work-pieces gives mass of zinc deposited. Also from
dimensions of work-piece, one can calculate surface
area and coating thickness. Initial dimensions (all in
mm) of plate are L=50.44, W=24.33, T=4 and of
cylinder are L=69.38 and D=22.36

Table 1 Information about electrolyte

Electrolyte Acidic Zinc Sulphate
Ph of electrolyte 5
Conductivity 6.5 σ/m
Temperature 30oC

Figure1 Model Geometry(center)

Table 2 Experimental Data of coating
thickness (µm) and coating weight (g) for plate This model uses the Deformed Geometry and Electric
Currents interfaces. The dynamics of the model is quasi-
Time(sec) Center Position Offset Position
static in nature, the time dependence only enters in the
deposition (addition of material) of electrode.
600 6.42 µm 2.83 µm
0.14 g 0.06 g
1200 13.8 µm 6.12 µm
0.3 g 0.13 g

Table 3 Experimental Data of coating

thickness (µm) and coating weight (g) for cylinder

Time(sec) Center Position Offset Position

600 8.92 µm 4.48 µm

0.36 g 0.17 g

1200 18.1 µm 8.43 µm

0.73 g 0.32 g
Figure 2 Model Geometry (Offset)
Coating thickness is calculated using the

  

formula:Coating thickness =
    


3.Simulation
Mileham et al (2002) [4]tells that modeling the
depletion of the positive electrode requires a moving
boundary because the geometry changes and the current
density distribution with it.Pryor, W.R(2011) [5] gives
us a simple model for the depletion is based on the
assumption that the depletion rate is proportional to the
normal current density at the electrode surface. The
velocity, U, normal to the mesh at the electrode surface

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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014, IIT
Guwahati, Assam, India

Figure 2 Coating thickness distribution for plate Figure 4 Coating thickness distribution for cylinder

From the above plot, we can see maximum coating From the above plot, we can see that since there are no
takesplace at the edges due to edge effects and sharp boundaries for cylinder, no edge effects are
minimum at the center. The coating thickness varies present and thus the coating seems quite uniform as
from 0.004mm(center) to 0.0142mm(edges). compared to plate. Here coating thickness is
approximately constant (19.31µm) over the surface.

Figure 5 Voltage Distribution for cylinder

Figure 3 Voltage Distribution for plate

The above plot shows the voltage distribution for the The above plot shows the voltage distribution for the
plate placed at center for 1200 sec. cylinder placed at center for 1200 sec.

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A STUDY OF ELECTROPLATING PROCESS THROUGH EXPERIMENT AND SIMULATION

4. Results
Experimental results were compared with edge effects of plate which results in non-uniformity in
simulations which helped in obtaining the plots given coating while this is not the case for cylinder because of
below. Compared here are variations of thickness with uniform circular surface and absence of edge effects
respect to time and voltage for center and offset which can be seen from very less deviation in error
positions. values for cylinder over the time.
6
25

Coating Thickness(µm)
5
Coating Thickness(µm)

20
4 Plate placed at center
Coating Thickness Plot(By 15 Plate placed at offset
3 Simulation)
Cylinder placed at center
10 Cylinder Placed at offset
2 Coating Thickness Plot(by
Experimentation)
5
1

0 0
0 200 400 600 800 1000 1200 1400 0 200 400 600 800 1000 1200 1400
Time(sec)

Figure 5 Coating thickness vs. Time plot for plate Figure 7 Coating thickness vs. Time plot for cylinder
placed at center. and plate placed at center and offset by simulation

25 35

30
20
Coating Thickness(µm)

Plate placed at center

Coating Thickness(µm)

25
15 20 Plate placed offset at 8.5 cm
from center
Coating Thickness Plot(by 15
10 Cylinder placed at center
simulation)
10
5
Cylinder placed offset at 8.5
Coating Thickness plot(by 5 cm from center
Experimentation)
0
0
0 5 10 15 20
0 200 400 600 800 1000 1200 1400
Time(sec) Voltage(V)

Figure 6 Coating thickness vs. Time plot for Figure 8 Coating thickness vs. Voltage plot for
cylinder placed at center. cylinder and plate placed at center and offset by
simulation
During the initial stages of coating, it can be seen that During the initial stages of plating, it can be seen that
there is not much difference in coating thickness for there is not much difference in variation of coating
experiment and simulation. But as time increases, it can thickness with respect to voltage and time for plate and
be seen there is aslight deviation between these two. cylinder placed at center and offset positions. But as
Deviation in simulation results for cylinder and time increases, it is seen there is a deviation between
plate placed at center for 20 minutes were observed to these two which implies coating thickness is
be 9.30% and 4.75% respectively while for 10 minutes, proportional to voltage, time and inversely proportional
they are 9.305% and 8.83%.This increase in error for to position of work-piece with respect to center of the
plate is more compared to that of cylinder because of electrolytic set up.

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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014, IIT
Guwahati, Assam, India

5. Conclusion
Broughton,K.(2011) [2] tells us that the use of
simulation modeling never serves as a substitute for
experimental data in determining if electroplating is
going to be fine. It does serve well as a reference to
assist in predicting how well experimentation may
perform. This paper incorporates the aspects of modern
research-simulation, experimentation and comparative
analysis. It can be concluded that as experimental time
increases, coating thickness increases. Also, coating
thickness is directly proportional to the voltage applied
across the electrodes. It is also observed that the
increase in distance of electrode from center position
decreases the amount of material deposited. Since the
error observed in simulation results are less than 10%, it
can be concluded that simulation is in accordance with
the experiment.

6. References
[1] Abou-Krisha,M.M (2005),Electrochemical studies
of zinc–nickel co-deposition in sulphate bath,Applied
Surface Science,Volume 252, Issue 4,pp. 1035–1048.
[2] Broughton,K.(2011),Microfluidic Micromixing. A
Tale of Two Processes:Simulation Vs.
Experimentation,Bioengineering 494,University of
Illinois-Chicago,Spring 2011.
[3] Budman, E., Sizelove, R.R. (1998), Zinc alloy
plating, Metal finishing, Volume 98, Number 1, 2000,
pp. 334-339(6).
[4]Mileham, A.R.,Bramley, A.N., Masuku, E.S.(2002),
A Finite Element Simulation of the Electroplating
Process, CIRP Annals - Manufacturing Technology,
Volume 51, Issue 1, pp. 169-172.
[5] Pryor, W.R(2011),"Multiphysics Modeling Using
Comsol".pp. 113-165.

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