Integrating Simulation and Electrochemical Insights for Nickel-Based MMC Coatings

The EU-funded MOZART project investigates nickel-based dispersion coatings incorporating nanoparticles as a viable alternative to hard chrome. This Mixed Metal Composite (MMC) approach has already demonstrated excellent mechanical properties, achieving hardness values up to 1000 HV.

Because nanoparticles do not undergo electrochemical discharge at the cathode, conventional electroplating models cannot predict their incorporation into the deposit. A major challenge lies in nanoparticle agglomeration, which can lead to precipitation and uneven distribution within the coating, particularly across surfaces with varying orientations. To address this, electrochemical characterization of plating bath chemistries is performed under different geometric conditions. These insights, combined with Computer-Aided Engineering (CAE) tools, enable prediction of particle content within the nickel matrix across complex component surfaces.

This contribution presents the integration of electroplating simulations with particle co-deposition modeling and highlights the design of plating tooling for multiple demonstrator parts. The proposed methodology establishes a framework for developing tailored tooling solutions, supporting the adoption of MMC coatings as a sustainable replacement for hard chrome.