Modelling and Simulation of the Coating Process on Open Porous Metal Foams

Abstract

AbstractBased on an increasing demand of energy and raw materials, resources should be used more efficiently. Therefore, multifunctional materials and lighter constructions, which can endure higher payloads, are needed. Cellular materials like metal foams are bionic, multifunctional materials, which can be optimised by a coating of the foam structure. Due to this coating via electrodeposition, the material properties per unit mass can be optimised. In consequence of the mass transport limitation inside the foam during the electrodeposition process, there occurs an inhomogeneous coating thickness distribution. To obtain a homogeneous coating thickness, in this project the factors are studied and simulated, which influence the electrochemical coating process. The electrodeposition process can be described by an ion source at the anode, the mass transport from anode to cathode and an ion sink at the cathode. The mass transport and the deposition process are characterised by the continuity equation with convection, diffusion, migration, a source term and a sink term. In this contribution, the factors influencing the coating thickness are investigated by numerical simulation to provide a homogeneous coating thickness. A material model is developed coupling mass transport with electrodeposition. A finite difference approach is used to simulate the ion concentration distribution inside the foam.