Alternative Plating Processes for Metal Electroplating Based on Ionic Liquids

WP-2316

Objective

The objective of this project is to accelerate the application of ionic liquids and other neoteric solvents in nonaqueous electroplating that addresses the Department of Defense (DoD) life‐cycle cost and environmental issues related to weapon systems. The team will explore the use of task‐specific ionic liquids and deep eutectic solvents (DES) that mitigate the issues of air/water‐stabilities concerning current electroplating baths for electrodeposition of aluminum. New methods of enhancing the conformal coating while mitigating the environmental stability and portable issues will be explored through development of flexible and adaptable plating baths based on ionogel and polymer gel membranes. In addition, the fundamental mechanisms that drive successful electroplating processes in these novel plating processes will be examined. Further, the stability of these nonaqueous plating baths under various operational environments will be investigated to determine the long‐term viability of these plating technologies. Finally, the technical issues regarding the use of ionic liquid plating baths—such as ionic liquid regeneration or the cycling, toxicity, and disposal of ionic liquids—will also be explored.

Back to Top

Technical Approach

To avoid using volatile and toxic organic solvents, chloroaluminate‐based ionic liquids have been intensively investigated in electroplating of aluminum. These ionic liquids can be conveniently prepared by combining anhydrous aluminum chloride‐1‐methyl‐3 (AlCl3) with an organic chloride such asethylmethyl imidazolium chloride (EMImCl) and N‐butylpyridinium chloride (N‐BPCl). Unfortunately, these ionic liquids can be used only in an inert‐gas atmosphere because of the hygroscopic nature of AlCl3 and the related chloroaluminate ionic liquids. In this work, the team will use air‐ and water‐stable ionic liquids and DES to investigate electroplating of aluminum. The effects of ionic structure, including cation types and anion types, surface activation properties, boundary layer effects of ionic liquids and additives, plating bath process variables, and coating properties, will be systematically investigated. In addition, a new conformal coating using a convenient wrap‐plating technique based on either an ionogel or a polymer gel membrane will be investigated. Finally, the technical issues regarding the use of ionic liquid plating baths—such as ionic liquid regeneration or the cycling, toxicity, and disposal of ionic liquids—will also be explored.

Back to Top

Benefits

The research will benefit DoD by providing a scientific understanding of the key mechanisms and process variables for using ionic liquids in electroplating aluminum. This research will enable the transition of promising ionic liquid processes into DoD’s maintenance and manufacturing systems. It will benefit DoD’s coating manufacturers and electronics assemblers by eliminating or reducing the use of hazardous materials in manufacturing and maintaining DoD systems. (Anticipated Project Completion - 2016)

Back to Top

Points of Contact

Principal Investigator

Dr. Sheng Dai

Oak Ridge National Lab

Phone: 865-576-7307

Fax: 865-576-5235

Program Manager

Weapons Systems and Platforms

SERDP and ESTCP

Document Types

  • Fact Sheet - Brief project summary with links to related documents and points of contact.
  • Final Report - Comprehensive report for every completed SERDP and ESTCP project that contains all technical results.
  • Cost & Performance Report - Overview of ESTCP demonstration activities, results, and conclusions, standardized to facilitate implementation decisions.
  • Technical Report - Additional interim reports, laboratory reports, demonstration reports, and technology survey reports.
  • Guidance - Instructional information on technical topics such as protocols and user’s guides.
  • Workshop Report - Summary of workshop discussion and findings.
  • Multimedia - On demand videos, animations, and webcasts highlighting featured initiatives or technologies.
  • Model/Software - Computer programs and applications available for download.
  • Database - Digitally organized collection of data available to search and access.