Cathode stripping behavior: Simulation by the finite element method and experimental effect of cathode surface roughness and its repeated use

Abstract

In order to increase productivity and reduce operating costs, a moderate adhesion between the electroplated metal and the mother blank is required. In this study, the influence of deposit thickness and adhesion strength on the stripping behavior of zinc deposits was investigated using finite element analysis (FEA), while the effect of cathode surface roughness and repeated use of the cathode (i.e., without intermediate brushing between plating cycles) was measured experimentally. The results showed that the aluminum cathode roughness increased with the number of plating cycles. The adhesion strength increased as the cathode roughness increased. Increasing the number of plating cycles also increased the amount of residual zinc particles on the aluminum surface. The FEA significantly improved the understanding of the stripping behavior. This analysis considered the adhesion, bending, and friction forces involved in the operation in relation to the stripping force. The bending force, which was found to be proportional to the variation in deposit thickness, represents the major component of the stripping force. Adhesion strengths have been shown to be responsible for the bend angle and consequently the amount of deposit deformation after stripping. The results of this study contribute to current knowledge and the implementation of operating conditions and routines that maximize productivity and reduce operating costs by reducing zinc sticking.