Development of novel electroplating tank layout by computer simulations and verification tests

Abstract

A novel modular tank layout, which flexibly adapts to various electroplating processes, is introduced and its feasibility has been studied by a three-dimensional simulation model. The new layout uses floor space and process volume more effectively and brings necessary novelty to the electroplating industry which partially suffers from outdated process equipment and low competitiveness. Trivalent chromium plating has been chosen as a test process in the simulation model since replacing hexavalent chromium is an important issue in the industry. The simulation model has been verified by conducting an extensive series of experimental coating thickness measurements and supplementing the model with these results. The results of the simulations support the feasibility of the new tank layout and show that it is possible to obtain good coating thickness uniformity when running separate coating processes simultaneously in one tank with different plating currents and surface areas of the objects to be plated.

Keywords:

• Electroplating
• Trivalent chromium
• Equipment design
• Modelling and simulation
• Finite element method

Acknowledgements

Jouko Turunen from the Savonia University of Applied Sciences is acknowledged for equipment design and Jussi Räisä from the Savonia University of Applied Sciences for guidance on experimental measurements. This study has been supported by the European Regional Development Fund projects LEKA and Investment and Development Project of Coating Technique by The Regional Council of Pohjois-Savo and by the Finnish Centre of Excellence in Inverse Problems Research, project 250215.