Modeling the electrodeposition process of copper on cobalt chrome

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Suggu, Santosh Kumar
Mahapatro, Anil

A simulation is a computer program that helps in creating a real time abstract model of a process. Using simulations the costs of conducting experiments have come down and this has achieved flexibility in terms of optimizing parameters and durations. Electrodeposition is a process that uses electrical current to reduce dissolved metal cations from anode so that they form a metal coating on cathode. Electrodeposition is widely used for many applications varying from anti-corrosion coatings, decorative purposes to high precision nanotechnology cloaking devices. The objective of this research was to predict the electrodeposition of copper on cobalt chrome enabling an efficient optimization of the deposition. The main governing equation used for this model was mass species conservation. COMSOL, finite element software was used to solve the governing equations. The model was simulated to predict coating thickness under different conditions such as, varying current density, concentration and deposition durations. Experiments were conducted to validate the results from the simulation. Electrodeposition was carried in an electrochemical cell with Co- Cr as cathode and Cu as anode with CuSO4 as an electrolyte. Coating thickness was determined using scanning electron microscope (SEM) and thickness gauge. There was an increasing trend in thickness in the both model and experiment when there was increase in current density. Decreasing trend was observed in the thickness in both model and experiment when there was reduction in the conductivity of the electrolyte. Model predicted results of the experiment at lower durations, at higher durations the experimental values deviated from the predicted values. These variations in the results were due to the limitations in the model and experimental verification methods, which could be worked in the future to reduce the variability.

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Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Industrial and Manufacturing Engineering