| Electrocodeposition is the process of particle incorporation during the electrodeposition of metal, which produces metal matrix composite films. The applications of these composite films include wear and abrasion resistant surfaces, high hardness tools, protection against oxidation and hot corrosion, and dispersion-strengthened alloys.; Although electrocodeposition is currently used to manufacture composite films, its use is limited due in part to the cost of the empirical approach currently used. A more effective use of electrocodeposition would require the ability to predetermine the process conditions necessary to achieve a particular film composition. However, such capability requires a comprehensive understanding of the electrocodeposition mechanism and its effect on the rates of metal and particle deposition, which has not been established. Thus, the overall objective of this research was to further understand the mechanism of electrocodeposition and the effects of process variables on particle incorporation.; A controlled hydrodynamic electrocodeposition cell was designed for mass transfer analysis of electrocodeposition of alumina particles in a copper matrix. This work investigated deposition conditions ranging from kinetically-controlled through mass-transfer limitations of the copper-alumina system, and also evaluated the effect of hydrodynamics, particle loading in suspension, particle characteristics (size and crystallographic phase), as well as electrode orientation. Particle incorporation was analyzed using a precise, reproducible technique developed in this investigation. |
