New Windows application identifies optimum coating thickness

Citation

(1998), "New Windows application identifies optimum coating thickness", Anti-Corrosion Methods and Materials, Vol. 45 No. 4. https://doi.org/10.1108/acmm.1998.12845daf.003

New Windows application identifies optimum coating thickness

New Windows application identifies optimum coating thickness

Keywords Coatings, Electroplating, Software, VTT

It is reported that a new Windows application developed by VTT Manufacturing Technology in Finland takes the guesswork out of the electroplating process, decreasing considerably the user's number of tests and rejects.

The development comes at the culmination of a series of fundamental changes in galvanic process technology applications. From its early days of being used mainly for decorative coatings, galvanic process technology now plays a key role in the production of technical coatings with precisely-defined functional properties, thickness and quality.

Increasingly, those using the technology ­ especially in the electroplating industry which aims at 100 per cent quality control ­ were frustrated by the lack of control. Frequent tests to ensure coating hindered output and the number of rejects impacted on profits.

VTT Manufacturing Technology linked with Ing. Buro Dr Pilz from Germany has developed the answer which has now been released commercially as the GalWin program (Plate4).

Plate 4 The screen shows: top left, the specimen coating. Top right is the galvanic plating layout where C represents the specimen. Using Galwin, the operator can place the anode (A), relevant shields (S) and auxiliary cathodes (AC) in the cell ­ and can take the electrolyte simple mixing into account. The simulation results show the relative current density distribution (bottom left) and the distribution of the coating thickness (bottom right). To identify the optimum thickness distribution, the anode, shields and auxiliary cathodes can be adjusted

The software, which runs in MS Windows environment, calls for a minimum 486-PC, 4Mb main memory, running Windows 3.1. It is also available in Windows NT or Windows 95 environments. What it offers is a simulation, leading to optimisation, of the industrial electro-plating process, operating through a simple interface.

The GalWin software permits the user to study the relative current density and the layer thickness distribution on the cathode surface. By making adjustments to the anode, shields and auxiliary cathodes on the GalWin model, the ideal thickness can be identified for a specific application.

Two major Finnish companies have reported substantial savings from installing GalWin. Kova-Kromi Oy/Hårdkrom Ab and Finnair Oy have used the process to simulate the hard chromium plating for metal valve pans and aeroplane pans. By using the software they have determined the optimum geometry and location of the coated pans, anodes, auxiliary anodes and shields in industrial scale production. This has led to their ability to optimise the uniformity of the chromium coating thickness, saving considerable manufacturing time and costs.

At Kova-Kromi/Hårdkrom Ab, the company has calculated a 70 per cent reduction of grinding time of the valve component ­ a considerable saving as the machining costs are often higher than the hard chromium plating costs. In addition, KovaKromi/Hårdkrom Ab has calculated that through optimising the hard chromium plating in their metal valve production area, the reduction in defective coatings is saving them 200,000FIM annually.

Details are available from VTT Manufacturing Technology, Tel: +358 9 4561; Fax: +358 9 463 118; Email: amar.mahiout@vtt.fi