The work aims to optimize multi-channel continuous nickel electroplating process for large-tow carbon fibers (CFs) and address the "black corn" defect of nickel coatings and the poor performance consistency of nickel-coated carbon fibers (CF@Ni) prepared by different channels, so as to reduce the preparation cost of CF@Ni for its large-scale industrial application. 24K carbon fiber was used as substrate material for nickel electroplating in a four-channel continuous production line. The surface sizing agent of CFs was removed before electroplating, as residual sizing agent would cause coating peeling or uneven deposition which was eliminated by high-temperature oxidation in air atmosphere with a tube furnace. The effects of electrolyte temperature, electroplating time, and current density on the surface morphology and physical properties of CF@Ni were also studied. The performance consistency of CF@Ni prepared from the four channels together was investigated through nickel content, linear resistance, coating thickness, and electrical conductivity. When CF underwent high-temperature degumming in air atmosphere, the residual sizing agent on its surface decreased continuously as the temperature rose, but its tensile strength dropped accordingly. When the electrolyte temperature was only 30 ℃, it would inhibit the nucleation rate of nickel atoms and the distribution of crystal grains, leading to discontinuous nickel coating and poor electrical conductivity. When it increased to 50 ℃, ion diffusion and reaction kinetics were optimized, resulting in dense and uniform nucleation, forming a continuous nickel coating. As electroplating time prolonged, the nickel grains on the CF surface tended to enlarge and the thickness of nickel coating increased linearly. However, excessive electroplating time caused the coating too thick, reducing the flexibility of CF@Ni. Current density precisely regulated the reduction amount of nickel ions, directly affecting the thickness uniformity, compactness and surface roughness of the nickel coating. It slowed down the reduction rate of nickel ions below 0.1 A/dm², causing thin coatings and occurrence of "black core". When the current density increased to 0.3 A/dm2, it formed a compact coating with uniform thickness on CF. However, when current density exceeded 0.4 A/dm2, it increased surface roughness and affected the corrosion resistance of CF@Ni. In terms of multi-channel performance consistency, the CF@Ni prepared under the optimized conditions from the four channels showed excellent consistency. The optimal temperature for removing the sizing agent of CF at high temperature in an air atmosphere was 400 ℃. When electrolyte temperature was 50 ℃, electroplating time was 8.0 min/m, and current density was 0.3 A/dm2, the 24K CF@Ni prepared by four channels exhibited no "black corn" defects and good performance consistency, with a nickel content maintained at 50wt.%-54wt.%, a linear resistance around 0.42-0.58 Ω/m, a nickel layer thickness of 0.32-0.37 μm per filament, and an electrical conductivity reaching 1.33- 1.48×108 S/m. The nickel coating is uniform and dense, with a tight interfacial bonding to CF. The CF@Ni retains the flexibility of CF and shows significantly improved oxidation resistance. Compared with the preparation of 24K CF@Ni by a single channel, the four-channel continuous preparation technology adopted in this work significantly improves production efficiency by 3 times, and the unit preparation cost is reduced by more than 50%. This technology is applicable to produce large-tow CF@Ni and any other specifications with the low cost, high quality, and large scale.
Key words
large-tow carbon fiber /
multi-channel /
degumming /
electrolyte temperature /
current density /
plating time
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
References
[1] 叶伟, 徐刘碗, 严仁杰, 等. 碳纤维金属化镀镍的研究进展[J]. 科技视界, 2015, 5(13): 8-10.
YE W, XU L W, YAN R J, et al.Research Progress in Nickel Coating on Carbon Fiber[J]. Science & Technology Vision, 2015, 5(13): 8-10.
[2] 王昆, 王一帆, 陈南梁. 金属化碳纤维连续制备方法及应用研究进展[J]. 复合材料学报, 2025, 42(4): 1795-1811.
WANG K, WANG Y F, CHEN N L.Advance in the Continuous Preparation Methods and Applications of Metallized Carbon Fiber[J]. Acta Materiae Compositae Sinica, 2025, 42(4): 1795-1811.
[3] 王富强, 刘鹏, 郭子民, 等. 基于镀镍碳纤维的低频电磁防护材料制备及性能研究[J]. 材料科学, 2018(10): 1002-1006.
WANG F Q, LIU P, GUO Z M, et al.Preparation of Low Frequency Electromagnetic Protection Material Based on Nickel-Plated Carbon Fiber and Performance Studies[J]. Material Sciences, 2018(10): 1002-1006.
[4] LANGOT J, GOURCEROL E, SERBESCU A, et al.Performance of Painted and Non-Painted Non-Woven Nickel-Coated Carbon Fibers for Lightning Strike Protection of Composite Aircraft[J]. Composites Part A: Applied Science and Manufacturing, 2023, 175: 107772.
[5] DARVISHZADEH A, NASOURI K. Manufacturing, Modeling,Optimization of Nickel-Coated Carbon Fabric for Highly Efficient EMI Shielding[J]. Surface and Coatings Technology, 2021, 409: 126957.
[6] 杨雅娜, 陈文革, 薛元琳. 碳纤维表面溅射金属增强铜基复合材料的界面结合[J]. 材料研究学报, 2021, 35(6): 467-473.
YANG Y N, CHEN W G, XUE Y L.Interficial Bonding within Cu-Based Composites Reinforced with TiC-or Ni-Coated Carbon Fiber[J]. Chinese Journal of Materials Research, 2021, 35(6): 467-473.
[7] ZHENG Y, ZHOU X R, LUO Y B, et al.Electrodeposition of Nickel in Air- and Water-Stable 1-Butyl-3- Methylimidazolium Dibutylphosphate Ionic Liquid[J]. RSC Advances, 2020, 10(28): 16576-16583.
[8] 贾晓菁, 张璋, 查萌. CVD参数对镀镍碳纤维原位生长CNFs形貌的影响及生长机理分析[J]. 化工新型材料, 2024, 52(5): 198-201.
JIA X J, ZHANG Z, ZHA M.Effects of CVD Parameters on the Morphology and the Mechanism Analysis of CNFS Grown In-Situ on Nickel-Plated Carbon Fiber[J]. New Chemical Materials, 2024, 52(5): 198-201.
[9] 乔英铭, 甘春雷, 曲迎东, 等. 工艺参数对连续碳纤维表面电磁搅拌化学镀镍的影响[J]. 表面技术, 2020, 49(5): 325-334.
QIAO Y M, GAN C L, QU Y D, et al.Effect of Technological Parameters on Electroless Nickel Plating of Continuous Carbon Fiber Surface with Electromagnetic Stirring[J]. Surface Technology, 2020, 49(5): 325-334.
[10] HOU X, CHEN H Y, XU C J, et al.Conductive Nickel/ Carbon Fiber Composites Prepared via an Electroless Plating Route[J]. Journal of Materials Science: Materials in Electronics, 2016, 27(6): 5686-5690.
[11] 张丽, 张彦. 化学镀的研究进展及发展趋势[J]. 表面技术, 2017, 46(12): 104-109.
ZHANG L, ZHANG Y.Research Progress and Development Trend of Chemical Plating[J]. Surface Technology, 2017, 46(12): 104-109.
[12] 高家诚, 谭尊, 任富忠. 碳纤维表面化学镀镍工艺及机理研究[J]. 功能材料, 2011, 42(8): 1360-1363.
GAO J C, TAN Z, REN F Z.Study on Kinetics and Technology of Ni Electroless Plating on Carbon Fibers[J]. Journal of Functional Materials, 2011, 42(8): 1360-1363.
[13] SCHLESINGER M, PAUNOVIC M.Modern Electroplating[M]. New York: Wiley, 2010: 79-110.
[14] 钱鑫, 韩卫东, 马洪波, 等. 电化学镀镍对PAN基高模量碳纤维结构及性能的影响[J]. 中国有色金属学报, 2022, 32(6): 1708-1718.
QIAN X, HAN W D, MA H B, et al.Effect of Electrochemical Nickel Plating on Structure and Properties of PAN-Based High Modulus Carbon Fibers[J]. The Chinese Journal of Nonferrous Metals, 2022, 32(6): 1708-1718.
[15] 邵友林, 王伯羲. 碳纤维的表面除胶及表征[J]. 复合材料学报, 2002, 19(4): 29-32.
SHAO Y L, WANG B X.Surface Desizing and Indication of Carbon Fiber[J]. Acta Materiae Compositae Sinica, 2002, 19(4): 29-32.
[16] 张敏, 朱波, 王成国, 等. 不同表面除胶工艺对碳纤维本体结构和表面结构的影响[J]. 功能材料, 2010, 41(9): 1565-1567.
ZHANG M, ZHU B, WANG C G, et al.Effect of Different Surface Desizing Technologies on the Bulk Structure and Surface Structure of Carbon Fibers[J]. Journal of Functional Materials, 2010, 41(9): 1565-1567.
[17] KIM G, LEE H, KIM K, et al.Effects of Heat Treatment Atmosphere and Temperature on the Properties of Carbon Fibers[J]. Polymers, 2022, 14(12): 2412.
[18] PIEROZYNSKI B.Electrodeposition of Nickel Onto 12K Carbon Fibre Tow in a Continuous Manner[J]. Croatica Chemica Acta, 2012: 1-8.
[19] 赵晓莉, 齐暑华, 刘建军, 等. 正交设计法优化碳纤维表面连续镀镍工艺及性能[J]. 工程塑料应用, 2019, 47(3): 55-59.
ZHAO X L, QI S H, LIU J J, et al.Optimization of Continuous Nickel Plating on Carbon Fiber Surface by Orthogonal Design[J]. Engineering Plastics Application, 2019, 47(3): 55-59.
[20] 杨斌, 刘敬萱, 齐亮, 等. 碳纤维表面镀镍工艺研究[J]. 有色金属科学与工程, 2016, 7(5): 49-54.
YANG B, LIU J X, QI L, et al.Surface Nickel Plating on Carbon Fiber[J]. Nonferrous Metals Science and Engineering, 2016, 7(5): 49-54.
[21] HUA Z S, LIU Y H, YAO G C, et al.Preparation and Characterization of Nickel-Coated Carbon Fibers by Electroplating[J]. Journal of Materials Engineering and Performance, 2012, 21(3): 324-330.
[22] 吕晓轩. 碳纤维表面电镀镍的界面形成机制及结构控制[D]. 太原: 中国科学院山西煤炭化学研究所, 2012: 29-48.
LYU X X.Study on the Formation Mechanism and Structural Control of Electroplating Nickel on Carbon Fibers[D]. Taiyuan: Institute of Coal Chemistry, Chinese Academy of Sciences, 2012: 35-48.
[23] 赵德明, 迟军科, 王丹, 等. 两种碳纤维上浆剂的比较[J]. 工程塑料应用, 2021, 49(3): 145-149.
ZHAO D M, CHI J K, WANG D, et al.Comparison on Two Kinds of Carbon Fiber Sizing Agents[J]. Engineering Plastics Application, 2021, 49(3): 145-149.
[24] 王庆辉. 碳纤维表面金属化及增强热塑性树脂复合材料的制备与性能研究[D]. 长春: 长春工业大学, 2025: 67-70.
WANG Q H.Preparation and Properties of Carbon Fiber Surface Metallized and Reinforced Thermoplastic Resin Composites[D]. Changchun: Changchun University of Technology, 2025: 67-70.
[25] LIU D D, LIU S, CHEN C, et al.The Interface Anchoring Effect of Nickel Nanoparticles on Carbon Nanotube/ Nickel/Copper Composite Wires with Ultra-High Conductivity and Current-Carrying Capacity[J]. Carbon, 2025, 244: 120611.
[26] MAJIDI M R, ASADPOUR-ZEYNALI K, HAFEZI B.Reaction and Nucleation Mechanisms of Copper Electrodeposition on Disposable Pencil Graphite Electrode[J]. Electrochimica Acta, 2009, 54(3): 1119-1126.
[27] GRUJICIC D, PESIC B.Electrodeposition of Copper: The Nucleation Mechanisms[J]. Electrochimica Acta, 2002, 47(18): 2901-2912.
PDF(4497 KB)
