The project's contribution extends beyond conventional studies by offering a comprehensive evaluation of the impact of different electrolytes on zinc and zinc-alloy electrodeposition. Considerations for environmental impact (through MCDA approach), corrosion resistance, and scalability provide a holistic perspective on the suitability of developed systems, contributing valuable insights. The study provides valuable insights into the use of halide-free non-aqueous systems for electrodeposition, addressing their environmental impact, safety, and scalability. Comparative assessments between conventional aqueous electrolytes and chloride-based DES contribute to the understanding of alternative electrolytes for electroplating applications. The inclusion of a cost analysis for the developed systems adds a practical dimension to the research. Considering the economic feasibility of these systems on an industrial scale, the study contributes to decision-making processes for adopting environmentally friendly alternatives in electroplating industries. Recycling the drag out solution (process solution transferring into subsequent rinse tanks) shall enhance the life of the halide free non aqueous-based plating solution, saving cost while eliminating the environmental impact of the process due to the drag out (reducing the source of pollutants). The plating solution and the rinse can be recycled many times without affecting the quality of the coatings formed, as long as the contamination level is closely monitored. This demonstrates that the process could be easily adopted to the current set up without increasing the capital expenditure.
This innovative low toxic environmentally responsible technology has been instrumental in expanding the realm of corrosion protection, and it has undergone a series of key developmental and testing phases.
The technology developed in this project has undergone rigorous testing and validation. Real-time parts were used in plating experiments conducted in a 5-liter plating line. The aim was to assess the plating performance of the novel halide-free non-aqueous plating electrolytes on industrially relevant test parts, specifically Norton panels. This testing included the deposition of zinc on mild steel and copper-based Norton panels under various conditions, such as temperature, plating times, and applied currents. The research not only confirmed the technology's preliminary techno economic viability but also provided valuable insights into the behavior of the plating bath and the coating process.
The setup and tests carried out in this study on halide free non-aqueous systems stand out unique and are pioneering, , marking a significant milestone in the development of corrosion-resistant coatings obtained via electroplating using low toxic halide free non-aqueous electrolytes. In the next phase of the project, further trials are planned on other industrial test parts like fasteners and brake calipers, demonstrating the versatility and applicability of the technology. These test parts will be plated with zinc and zinc-based alloys using the novel halide-free non-aqueous plating electrolytes, showcasing the environmentally friendly aspects of the technology.
The innovation activities in this project have encompassed the selection of halide-free ILs, organic solutions and DESs, the development of coatings employing these electrolytes, and the rigorous testing and validation of the technology on real industrial test parts. The results of this work hold great promise for advancing corrosion protection and opening up new avenues for the use of halide-free non-aqueous plating electrolytes in various applications, with plans to showcase these innovations at exhibitions in the near future.
