Abstract: In this research, zinc coatings were fabricated by electroplating process in a sulfate solution under direct and pulse current conditions. In direct and pulse current conditions, effect of maximum current was investigated on the coating properties. Also a comparison was made between the obtained coatings under direct and pulse current. Morphology of the coatings was investigated by scanning electron microscopy (SEM). Corrosion behavior of the coatings was investigated by potentiodynamic polarization test. In pulse current conditions, the effect of pulse frequency and duty cycle was also studied. The effect of these conditions and parameters were also investigated on morphology and corrosion behavior. All of DC plated coatings are showing a distinct passivation area in -1 to -0.4 V range. Pulsed current coatings possessed a higher corrosion resistance. The results showed that current density is the most important factor regarding the fabrication process. Furthermore, a rise in duty cycle deteriorated corrosion resistance of coatings. Pulsed plated coatings performed almost 10 times better than DC plated coatings.
Abstract: The process of post-supercritical CO2 electroplating uses the electrolyte solution after being mixed with supercritical CO2 and released to atmospheric pressure. It utilizes the microbubbles that form when oversaturated CO2 in the electrolyte returns to gaseous state, which gives the similar effect of pulsed electroplating. Under atmospheric pressure, the CO2 bubbles gradually diffuse. Therefore, the introduction of ultrasound and/or other agitation can potentially excite the CO2 microbubbles to achieve an electroplated surface of even higher quality. In this study, during the electroplating process, three different modes of agitation: magnetic stirrer agitation, ultrasonic agitation and a combined mode (magnetic + ultrasonic) were applied, respectively, in order to obtain an optimal surface morphology and mechanical properties for the electroplated Ni coating. It is found that the combined agitation mode at a current density of 40 A/dm2 achieved the smallest grain size, lower surface roughness, and produced an electroplated Ni layer that achieved hardness of 320 HV, much higher when compared with conventional method, which were usually in the range of 160 to 300 HV. However, at the same time, the electroplating with combined agitation developed a higher internal stress of 320 MPa due to the lower current efficiency of the process and finer grain in the coating. Moreover, a new control methodology for tailoring the coating’s mechanical property through its thickness was demonstrated by the timely introduction of ultrasonic agitation during the electroplating process with post supercritical CO2 mixed electrolyte.
Abstract: In this preliminary work, locally available husk of Cajanus cajan (commonly known in India as Tur or Arhar), a bio-waste, has been used in its physically treated and chemically activated form for the removal of binary Cu (II) and Zn(II) ions from the real waste water obtained from an electroplating industry in Bangalore, Karnataka, India and from laboratory prepared binary solutions having almost similar composition of the metal ions, for comparison. The real wastewater after filtration and dilution for five times was used for biosorption studies at the normal pH of the solutions at room temperature. Langmuir's binary model was used to calculate the metal uptake capacities of the biosorbents. It was observed that Cu(II) is more competitive than Zn(II) in biosorption. In individual metal biosorption, Cu(II) uptake was found to be more than that of the Zn(II) and a similar trend was observed in the binary metal biosorption from real wastewater and laboratory prepared solutions. FTIR analysis was carried out to identify the functional groups in the industrial wastewater and EDAX for the elemental analysis of the biosorbents after experiments.
Abstract: Zn alloy and composite coatings are widely used in
buildings and structures, automobile and fasteners industries to
protect steel component from corrosion. In this paper, Zn-Ni-Al2O3
nanocomposite coatings were electrodeposited on mild steel using a
novel sol enhanced electroplating method. In this method, transparent
Al2O3 sol was added into the acidic Zn-Ni bath to produced Zn-Ni-
Al2O3 nanocomposite coatings. The effect of alumina sol on the
electrodeposition process, and coating properties was investigated
using cyclic voltammetry, XRD, ESEM and Tafel test. Results from
XRD tests showed that the structure of all coatings was single γ-
Ni5Zn21 phase. Cyclic voltammetry results showed that the
electrodeposition overpotential was lower in the presence of alumina
sol in the bath, and caused the reduction potential of Zn-Ni to shift to
more positive values. Zn-Ni-Al2O3 nanocomposite coatings produced
more uniform and compact deposits, with fine grained microstructure
when compared to Zn-Ni coatings. The corrosion resistance of Zn-Ni
coatings was improved significantly by incorporation of alumina
nanoparticles into the coatings.
Abstract: Sol-enhanced Zn-Ni-Al2O3 nanocomposite coatings
were electroplated on mild steel by our newly developed solenhanced
electroplating method. In this method, transparent Al2O3 sol
was added into the acidic Zn-Ni bath to produced Zn-Ni-Al2O3nanocomposite
coatings. The chemical composition, microstructure and
mechanical properties of the composite and alloy coatings deposited
at two different agitation speed were investigated. The structure of all
coatings was single γ-Ni5Zn21 phase. The composite coatings possess
refined crystals with higher microhardness compared to Zn-Ni alloy
coatings. The wear resistance of Zn-Ni coatings was improved
significantly by incorporation of alumina nano particles into the
coatings. Higher agitation speed provided more uniform coatings
with smaller grain sized and slightly higher microhardness.
Considering composite coatings, high agitation speeds may facilitate
co-deposition of alumina in the coatings.
Abstract: This research studies the electroplating of zinc coating
in the zinc chloride bath mixed with supercritical CO2. The sodium
fluoride (NaF) was used as the bath additive to change the structure
and property of the coating, and therefore the roughness and corrosion
resistance of the zinc coating was investigated. The surface
characterization was performed using optical microscope (OM), X-ray
diffractometer (XRD), and α-step profilometer. Moreover, the
potentiodynamic polarization measurement in 3% NaCl solution was
employed in the corrosion resistance evaluation. Because of the
emulsification of the electrolyte mixed in Sc-CO2, the electroplated
zinc produced the coating with smoother surface, smaller grain, better
throwing power and higher corrosion resistance. The main role played
by the NaF was to reduce the coating’s roughness and grain size. In
other words, the CO2 mixed with the electrolyte under the supercritical
condition performed the similar function as brighter and leveler in zinc
electroplating to enhance the throwing power and corrosion resistance
of the coating.
Abstract: The presence of toxic heavy metals in industrial
effluents is one of the serious threats to the environment. Heavy
metals such as Cadmium, Chromium, Lead, Nickel, Zinc, Mercury,
Copper, Arsenic are found in the effluents of industries such as
foundries, electroplating, petrochemical, battery manufacturing,
tanneries, fertilizer, dying, textiles, metallurgical and metal finishing.
Tremendous increase of industrial copper usage and its presence in
industrial effluents has lead to a growing concern about the fate and
effects of Copper in the environment. Percolation of industrial
effluents through soils leads to contamination of ground water and
soils. The transport of heavy metals and their diffusion into the soils
has therefore, drawn the attention of the researchers.
In this study, an attempt has been made to delineate the
mechanisms of transport and fate of copper in terrestrial
environment. Column studies were conducted using perplex glass
square column of dimension side 15 cm and 1.35 m long. The soil
samples were collected from a natural drain near Mohali (India). The
soil was characterized to be poorly graded sandy loam. The soil was
compacted to the field dry density level of about 1.6 g/cm3. Break
through curves for different depths of the column were plotted. The
results of the column study indicated that the copper has high
tendency to flow in the soils and fewer tendencies to get absorbed on
the soil particles. The t1/2 estimates obtained from the studies can be
used for design copper laden wastewater disposal systems.
Abstract: In this study, a nickel film with nano-crystalline grains,
high hardness and smooth surface was electrodeposited using a post
supercritical carbon dioxide (CO2) mixed Watts electrolyte. Although
the hardness was not as high as its Sc-CO2 counterpart, the thin coating
contained significantly less number of nano-sized pinholes. By
measuring the escape concentration of the dissolved CO2 in post
Sc-CO2 mixed electrolyte with the elapsed time, it was believed that
the residue of dissolved CO2 bubbles should closely relate to the
improvement in hardness and surface roughness over its conventional
plating counterpart. Therefore, shortening the duration of
electroplating with the raise of current density up to 0.5 A/cm2 could
effectively retain more post Sc-CO2 mixing effect. This study not only
confirms the roles of dissolved CO2 bubbles in electrolyte but also
provides a potential process to overcome most issues associated with
the cost in building high-pressure chamber for large size products and
continuous plating using supercritical method.
Abstract: Simultaneous recovery of copper and DCA from
simulated MEUF concentrated stream was investigated. Effects of
surfactant (DCA) and metal (copper) concentrations, surfactant to
metal molar ratio (S/M ratio), electroplating voltage, EDTA
concentration, solution pH, and salt concentration on metal recovery
and current efficiency were studied. Electric voltage of -0.5 V was
shown to be optimum operation condition in terms of Cu recovery,
current efficiency, and surfactant recovery. Increasing Cu recovery and
current efficiency were observed with increases of Cu concentration
while keeping concentration of DCA constant. However, increasing
both Cu and DCA concentration while keeping S/M ratio constant at
2.5 showed detrimental effect on Cu recovery at DCA concentration
higher than 15 mM. Cu recovery decreases with increasing pH while
current efficiency showed an opposite trend. It is believed that
conductivity is the main cause for discrepancy of Cu recovery and
current efficiency observed at different pH. Finally, it was shown that
EDTA had adverse effect on both Cu recovery and current efficiency
while addition of NaCl salt had negative impact on current efficiency
at concentration higher than 8000 mg/L.
Abstract: A real time image-guided electroplating system is
proposed in this paper. Unlike previous electroplating systems, instead
of using the intermittent mode to electroplate 500um long copper
specimen, a CCD camera and a motion controller are used to adjust
anode-cathode distance to obtain better results. Since the image of the
gap distance is highly deteriorated due to complex chemical-electrical
operation inside the electrolyte, to determine the gap distance, an
image processing algorithm is developed and mainly based on the
entropy and energy values. In addition, the color and incidence
direction of light source are also discussed to help the image process in
this paper. From the experiment results, the specimens created by the
proposed system show better structure, better uniformity and better
finishing surface compared to those by previous intermittent
electroplating setup.
Abstract: In this study, the designed dual stage membrane
bioreactor (MBR) system was conceptualized for the treatment of
cyanide and heavy metals in electroplating wastewater. The design
consisted of a primary treatment stage to reduce the impact of
fluctuations and the secondary treatment stage to remove the residual
cyanide and heavy metal contaminants in the wastewater under
alkaline pH conditions. The primary treatment stage contained
hydrolyzed Citrus sinensis (C. sinensis) pomace and the secondary
treatment stage contained active Aspergillus awamori (A. awamori)
biomass, supplemented solely with C. sinensis pomace extract from
the hydrolysis process. An average of 76.37%, 95.37%, 93.26 and
94.76% and 99.55%, 99.91%, 99.92% and 99.92% degradation
efficiency for total cyanide (T-CN), including the sorption of nickel
(Ni), zinc (Zn) and copper (Cu) were observed after the first and
second treatment stages, respectively. Furthermore, cyanide
conversion by-products degradation was 99.81% and 99.75 for both
formate (CHOO-) and ammonium (NH4
+) after the second treatment
stage. After the first, second and third regeneration cycles of the C.
sinensis pomace in the first treatment stage, Ni, Zn and Cu removal
achieved was 99.13%, 99.12% and 99.04% (first regeneration cycle),
98.94%, 98.92% and 98.41% (second regeneration cycle) and 98.46
%, 98.44% and 97.91% (third regeneration cycle), respectively.
There was relatively insignificant standard deviation detected in all
the measured parameters in the system which indicated
reproducibility of the remediation efficiency in this continuous
system.