超声辅助电沉积金属基镀层的研究进展

王颖慧; 刘洪军; 张靖宇; 李亚敏

doi:10.16490/j.cnki.issn.1001-3660.2026.02.014

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表面技术 ›› 2026, Vol. 55 ›› Issue (2) : 194-208. DOI: 10.16490/j.cnki.issn.1001-3660.2026.02.014

功能表面及技术

超声辅助电沉积金属基镀层的研究进展

王颖慧^1a, 刘洪军^1a,1b,*, 张靖宇^1a,2, 李亚敏^1a

作者信息 +

Research Progress on Ultrasonic-assisted Electrodeposition of Metal Based Coatings

WANG Yinghui^1a, LIU Hongjun^1a,1b,*, ZHANG Jingyu^1a,2, LI Yamin^1a

Author information +

文章历史 +

摘要

超声辅助电沉积（Ultrasonic-Assisted Electrodeposition）是一种将高强度超声波与电沉积过程耦合的表面技术,通过超声空化现象与电场驱动的协同作用,实现纯金属、合金及其复合镀层在基体材料表面的可控沉积。由于具有工艺调控灵活、资源利用率高、环境友好等优势,该技术的应用领域已从传统的表面强化拓展至航空航天、微电子、新能源器件、生物材料等领域的新材料制备。本文介绍了超声辅助电沉积时超声空化现象及其产生的物理效应,对比分析了超声浴槽和超声探头两种超声引入模式的特征及适用场景。基于超声波在细化镀层晶粒、改变镀层成分以及降低孔隙率等方面的作用以及改善颗粒在电解液中分散性的效果,系统讨论了超声辅助技术对电沉积金属基镀层在分散搅拌、晶粒细化和性能改善方面的作用,并详细总结了该技术在铜、镍、铁、锡等金属、合金及其复合镀层制备方面的研究进展。此外,本文还指出了作用机制、工艺优化和性能预测、多物理场耦合、新型电解液、规模化应用等方面的挑战和未来发展方向。

Abstract

Ultrasonic-assisted electrodeposition is a surface technology that integrates high-intensity ultrasound with the electrodeposition process. By leveraging the synergistic effects of acoustic cavitation and electric field driving forces, it enables the controlled deposition of pure metals, alloys, and their composite coatings onto substrate materials. Owing to its advantages of flexible process control, high resource utilization efficiency, and environmental friendliness, its application has expanded beyond traditional surface strengthening to the preparation of new materials in fields such as aerospace, microelectronic, new energy devices, and biomaterials. Firstly, the paper describes the phenomenon of acoustic cavitation during ultrasonic-assisted electrodeposition and its resultant physical effects, which can reduce the thickness of the diffusion layer, clean the electrode surface, and promote electron transfer on the electrode surface. Then, two primary introduction methods of ultrasound, ultrasound bath and ultrasound probe, are compared and analyzed. The ultrasonic bath method is simple to construct and cost-effective. The transducer usually operates at a low amplitude, which reduces transmission efficiency but evenly distributes energy, forming a stable ultrasonic field and avoiding local energy concentration. The ultrasound probe method has low energy loss, high local processing accuracy, and high cavitation intensity. However, strong cavitation may cause corrosion of the cathode surface, local overheating, and coating damage, so low-power operation is generally used. Based on the effects of ultrasonic in refining coating grains, reducing porosity, altering coating composition, and improving the dispersion of particles in the electrolyte, the role of an ultrasonic-assisted technology in electroplated metal based coatings is systematically discussed in terms of dispersion and stirring, grain refinement, and property enhancement. Compared with mechanical stirring and bubble stirring, ultrasonic stirring effectively alleviates concentration polarization by disrupting the diffusion layer and enhancing mass transfer. Its micro flow field disturbance can also improve cathode current efficiency. When electrodepositing composite coatings, ultrasound has a more significant de-agglomeration effect and better dispersibility on particles in the electrolyte. After introducing ultrasonic stirring during the electrodeposition process, cavitation effect and acoustic flow promote the fragmentation of coarse grains and nucleation, reduce the critical grain size and concentration polarization, thereby significantly refine the coating grains. The ultrasonic-assisted electrodeposition process can prepare coatings with fine grains, dense structure, and good dispersion of enhanced particles, thus making the coatings possess high strength, excellent wear resistance, and corrosion resistance. High-performance copper and copper based coatings are highly in line with the current demand in fields such as electronic circuits, new energy batteries, and biomaterials. Especially, high-quality composite effects have been achieved in the preparation of graphene/copper composite coatings. In nickel based coatings, the main focus is on improving wear resistance and corrosion resistance. Furthermore, the research progress in the preparation of iron, tin, and other metals, alloys, as well as their composite coatings is summarized, covering protective coatings, functional alloys, and special substrate treatments. Additionally, although this paper highlights the prospects of this technology in material design, performance control, and new structure synthesis, the challenges are also outlined, focusing on the understanding underlying mechanisms between cavitation effect and electrodeposition process, process optimization and property prediction, multi-physics field coupling, novel electrolytes development, and scaling up for industrial applications. Corresponding future directions are also proposed.

导出引用

王颖慧, 刘洪军, 张靖宇, 李亚敏. 超声辅助电沉积金属基镀层的研究进展[J]. 表面技术. 2026, 55(2): 194-208

WANG Yinghui, LIU Hongjun, ZHANG Jingyu, LI Yamin. Research Progress on Ultrasonic-assisted Electrodeposition of Metal Based Coatings[J]. Surface Technology. 2026, 55(2): 194-208

中图分类号： TQ153

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