Modelling and verification of the nickel electroforming process of a mechanical vane fit for Industry 4.0

• DOI: 10.1016/j.dche.2024.100177
• Publication Date: 2024-08-18T05:34:33Z
• Authors: Eleni Andreou; Sudipta Roy
• Keywords: Electroforming

In previous studies, the comprehensive scaling-up of nickel electroforming on a lab-scale rotating disk electrode (RDE) suggested that secondary current distribution could adequately simulate such forming process. this work, use 3-D, time-dependent, model, developed in COMSOL Multiphysics®, was examined to validate an industrial mechanical vane, low-tolerance part with demanding thickness profile great interest aerospace industry. A set experiments were carried out pilot tank computations showing model can satisfactorily predict experimental findings. addition, these revealed local applied density related surface appearance (shiny vs matt) electroform. Simulations process at densities ≤5A/dm2 predicted experimentally observed while, simulations ≥5A/dm2 underpredicted achieved thicknesses. Nevertheless, it is proposed be used for either quantitative or qualitative respectively, depending required operating case-by-case basis. Scanning electron microscopy determine microstructure electroforms and purity (i.e., if oxide formed), imaging suggesting pyramid-shaped particles evolve during deposition. Another interesting observation periodicity deposit's growth mechanism which leads "necklace"-like deposit layers areas where presented highest thickness.