3D simulation and validation of a Ni plating process for reflector applications

Due to the high uniformity demands, nickel deposition processes for producing reflector coatings often make use of dedicated plating cell configurations. Computer simulations can drastically speed up the trial and error stage for optimizing the plating cell design. In this paper, the nickel deposition distribution for a reflector application is simulated using the Elsyca PlatingMaster software tool. Results are compared to experimentally mapped data over the deposition surface. The quantative accuracy of the simulation results depends upon the electrolyte bath characteristics input. Dedicated laboratory measurements are performed (Rotating Disc Electrode set-up) to produce reliable electrolyte bath characteristics for different bath concentrations and operating temperatures. Simulations which make use of these dedicated input data turn out to match closely the experimental results. This observation justifies the cost of manpower and equipment for measuring relevant plating bath characteristics to be used in the Elsyca PlatingMaster software tool before performing any simulations for plating cell optimization: