Research Progress on Ultrasonic-assisted Electrodeposition of Metal Based Coatings

WANG Yinghui; LIU Hongjun; ZHANG Jingyu; LI Yamin

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

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

Functional Surfaces and Technology

Research Progress on Ultrasonic-assisted Electrodeposition of Metal Based Coatings

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

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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.

Key words

surface engineering / ultrasonic / electrodeposition / metal based coatings / new materials

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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

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Funding

Joint fund between Shenyang National Laboratory for Materials Science and State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals (18LHPY008)