Multi-Physics Simulation and Optimization of Jet Electrodeposition for Ni-Diamond Composite Coatings

Abstract

This work investigated the influence of current density, plating solution flow rate, and nozzle outlet-to-cathode distance on the properties of Ni-diamond composite coatings. A multi-physics field simulation was employed to analyze the interplay between current density, plating solution flow rate, and nozzle outlet-to-cathode distance on the flow field and electric field distribution. Additionally, particle tracing simulations were incorporated into the model to evaluate the incorporation efficiency of diamond particles during composite electrodeposition. It was found that when the inlet flow rate of the electrolyte was 5 L/min, the distance between the nozzle outlet and the cathode was 3 mm, and the current density was 60 A/dm2, the composite electrodeposited coating had a higher particle content and better uniformity. The simulation results were validated through experimental preparation and performance testing. This combined approach provides valuable insights for optimizing the jet electrodeposition process for Ni-diamond composite coatings with superior properties.