Novel Multiphysics Modeling of Electroplating Process for Metallic Aerospace Components

Electroplating is a popular method for applying a variety of coatings, including Zn-Ni, to metal substrates. However, these coatings can suffer from hydrogen embrittlement and residual stress, which can negatively impact fatigue strength. To better understand these issues, Technical Data Analysis Inc. (TDA) and the University of Cincinnati have joined forces in an STTR effort to develop a cutting-edge computational framework that uses multi-physics and multi-scale models. By applying these techniques, we can gain insight into the microstructure and properties of the coatings and the mechanisms behind hydrogen embrittlement and residual stress.  During Phase II, TDA will focus its efforts on Developing an electroplating CAE software (EP-Software) to assist in improving the production quality and performance of Zn-Ni electroplated components - The software will help in the specific design and optimization of parts to be plated, anodes, shields (masking), and tank configuration. Investigating mechanisms, modeling, and experimental testing of Zn-Ni electroplating process- Here we focus on two aspects: (a) origins of residual stress from the effects of lattice mismatch and of formation of high-pressure gas, (b) quantifying the residual stress at the interface and through the substrate thickness. Developing concept for digital twin for electroplating process - TDA will conduct initial studies towards the development smart tank and digital twin technology. To create a virtual testbed, we will develop a plan for sensors and other monitoring devices to collect data on various parameters such as temperature, pH level, current density, and plating time. This data can then be fed into a digital twin model which would simulate the electroplating process in real-time. This effort is more towards building a framework and plan for future work and initiatives.  The above efforts lead to the assessment of coating quality for consistency and uniformity, and prediction the impact of defects, residual stress, hydrogen ingress, and the environment on the fatigue strength of high strength steel (HSS) aerospace components. Key investigations of the approach include: 1) the development of an electro-chemo-mechanical electroplating simulation using multi-physics and multi-scale models; 2) the creation of an electroplating CAE tool for Zn-Ni coating; and 3) the performance of critical sets of experiments to validate the electroplating simulation module and identify plating defects' types and causes. The framework will allow engineers to reliably predict electrochemical and mechanical behavior and suggest design parameters to optimize the electroplating process for aerospace components, eliminating the need for multiple experimental trials.