CHAPTER III EXPERIMENTAL TECHNIQUES
Transcript of CHAPTER III EXPERIMENTAL TECHNIQUES
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CHAPTER III
EXPERIMENTAL TECHNIQUES
3.1 Electrodeposition Since electrodeposition is highly diverse in nature, no single universal
experimental procedure has been found satisfactory to cover all aspects of
electrodepositon of metals and alloys. However, it is very essential to select relevant
methods to correlate laboratory experiments with actual industrial operations [1-5].
Though absolute reproducibility is rather difficult to achieve due to several factors,
reproducibility with minimum error is of considerable importance.
3.1.1 Chemicals and materials used
Chemicals Make
Tri chloro ethylene Fischer, India
Agar-Agar CDH, India
Potassium chloride Ranbaxy, India
Sulfuric acid Fischer, India
Nitric acid Fischer, India
Hydrochloric acid Fischer, India
Sodium hydroxide ` Fischer, India
Sodium carbonate Fischer, India
Copper sulfate BDH, India
Copper carbonate (basic) S.d.fine chemicals, India
Methane sulphonic acid (100 %) Merck India
EDTA BDH, India
Lead carbonate Merck, India
Lead fluoborate Madras fluorine chemicals, Chennai
Hydrofluoric acid S.d.fine chemicals, India
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Boric acid Sarabhai chemicals, India
Sodium chloride Ranbaxy, India
Potassium ferry cyanide Ranbaxy, India
Peptone CDH, India
Gelatin CDH, India
Poly ethylene glycol (4000) Ranbaxy, India
Triton-X-100 Merck, India
Stannous oxide CDH, India
Tin fluoborate Madras fluorine chemicals, Chennai.
Iodine Merck, India
Potassium Iodide S.d.fine chemicals, India
Double distilled water was used for the preparation of experimental solutions.
All glassware and electrochemical apparatus were fabricated at Central
electrochemical research institute, Karaikudi, India. A single pan digital balance
(Afcoset Model ER-180A) was used for mass measurements to determine current
efficiency, throwing power, thickness etc.
The current and potential were measured using digital multimeters. The digital
power source (Aplab 0-2 A, 0-32 V) was employed as the DC power supply unit for
electrodeposition. Polarisation studies were carried out using a constant current regulator
(fabricated at Central electrochemical research institute, Karaikudi, India.)
3.2 Preparation and purification of electrolytes
3.2.1 Copper methane sulphonate bath
Required amount of basic copper carbonate was weighed and transferred into a
beaker. Required amount of methane sulphonic acid was added to this and the dissolved
in double distilled water. The suspended impurities present in the solution were removed
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by filtration. The organic and inorganic impurities were removed by treatment with
activated charcoal and dummy electrolysis respectively.
The amount of copper present in the electrolyte was estimated by complexometric
titration using EDTA. The basic bath compositions of copper methane sulphonate bath
used for the studies such as Hull-cell, current efficiency, throwing power measurements;
polarization, and samples preparation for testing mechanical properties and corrosion
studies is given in the table 3.1.
3.2.2 Copper sulphate bath
The sulphate based copper bath was prepared as and when required. A calculated
quantity of copper sulphate was exactly weighed and transferred into the beaker, with this
required volume of sulphuric acid was added slowly and made up with distilled water.
The suspended impurities present in the solution were removed by filtration. The organic
and inorganic impurities were removed by treatment with activated charcoal and dummy
electrolysis respectively.
The basic bath composition of copper sulphate bath used for the studies such as
Hull-cell, current efficiency, throwing power measurements; polarization, and samples
preparation for testing mechanical properties and corrosion studies is given in the table
3.1.
3.2.3 Lead methane sulphoante bath
Required amount of lead carbonate was weighed and transferred into a beaker. To
this the required amount of methane sulphonic acid was added and heated to 70-75oC,
After complete dissolution of the salt dissolved, the solution was made up to the required
volume with double distilled water. The suspended impurities present in the solution
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Table 3.1 Composition of baths studied
Bath Constituents
A Copper (as methane sulphonate) 0.70- 0.10 M
MSA 0.31–0.73 M
Temperature RT (30oC)
B Copper (as copper sulphate) 0.70- 0.10 M
Sulfuric acid 0.31 - 0.73 M
Temperature RT (30oC)
C Lead (as methane sulphonate) 0.24- 0.48 M
MSA 0.21- 0.63 M
Temperature RT (30oC)
D Lead (as fluoborate) 0.24- 0.48 M
Fluoboric acid 0.21- 0.63 M
Boric acid 0.48 M
Temperature RT (30oC)
E Tin (as methane sulphonate) 0.33 – 0.50 M
MSA 1.56 – 2.60 M
Temperature RT (30oC)
F Tin (as fluoborate) 0.33- 0.50 M
Fluoboric acid 1.56 –2.60M
Boric acid 0.48 M
Temperature RT (30oC)
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were removed by filtration. The organic and inorganic impurities were removed by
treatment with activated charcoal and dummy electrolysis respectively.
The amount of lead present in the electrolyte was estimated by
complexometric titration using EDTA. The basic bath composition of lead methane
sulphonate used for the studies such as Hull-cell, current efficiency, throwing power
measurements; polarization, and samples preparation for testing mechanical properties
and corrosion studies is given in the table 3.1.
3.2.4 Preparation of fluoboric acid
Fluoboric acid was prepared by adding analar grade boric acid in small
increments with constant stirring to a chemically pure hydrofluoric acid (40 wt %) in the
stochiometric ratio as per the following equation
4 HF + H3BO3 HBF4 + 3 H2O
The presence of unreacted hydrofluoric acid was tested by the formation of white
precipitate with a sample of lead nitrate solution. The strength of fluoboric acid was
estimated by acid-base titration. The concentration of fluoboric acid was varied by
diluting this acid.
3.2.5 Lead fluoborate bath
Required amount of commercially available lead fluoborate solution
(approx.50%) was taken in a polyethylene beaker. To this, required quantities of
fluoboric acid and boric acid were added and then the solution made up to the required
volume with double distilled water. The suspended impurities present in the solution
were removed by filtration. The organic and inorganic impurities were removed by
treatment with activated charcoal and dummy electrolysis respectively.
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The amount of lead present in the electrolyte was estimated by complexometric
titration using EDTA. The basic bath composition of lead fluoborate used for the studies
such as Hull-cell, current efficiency, throwing power measurements; polarization and
samples preparation for testing mechanical properties and corrosion studies is given in
the table 3.1.Boric acid was added to avoid the hydrolysis of fluoboric acid.
3.2.6 Tin methane sulphonate bath
Required amount of stannous oxide was weighed and taken in a beaker. Required
amount of methane sulphonic acid was added and heated to 80oC. After complete
dissolution of the salt, the solution was filtered and made up with double distilled water.
The suspended impurities present in the solution were removed by filtration. The organic
and inorganic impurities were removed by treatment with activated charcoal and dummy
electrolysis
The amount of tin present in the electrolyte was estimated by iodometric
titration using starch as indicator. The basic bath composition of tin methane sulphonate
bath used for the studies such as Hull-cell, current efficiency, throwing power
measurements; polarization, and samples preparation for testing mechanical properties
and corrosion studies is given in the table 3.1.
3.2.7 Tin fluoborate electrolyte
Required amount of commercially available tin fluoborate solution (approx.50%)
was taken in a polyethylene container. Required quantity of fluoboric acid and boric acid
was added and then made up with double distilled water. The suspended impurities
present in the solution were removed by filtration. The organic and inorganic impurities
were removed by treatment with activated charcoal and dummy electrolysis respectively.
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The amount of tin present in the electrolyte was estimated by iodometric
titration using starch as indicator. The basic bath composition for tin fluoborate bath
used for the studies such as Hull-cell, current efficiency, throwing power measurements;
polarization, cyclic voltammetry, and samples preparation for testing mechanical
properties and corrosion studies is given in the table 3.1.
3.3 Electrodes and cells
3.3.1 Electrodes
Anodes Electrolytic copper (99.5 % pure)
Electrolytic lead (99.5 % pure)
Electrolytic tin (99.5 % pure)
Cathodes Mild steel (for tin, lead, deposition)
Brass (for copper deposition)
3.3.2 Hull Cell [6]
It is a small trapezoidal cell of accurate dimensions. Figure.3.1 shows the cross
sectional and over view of a Hull-cell. It is of different capacities, 1000 ml, 320 ml and
267 ml. Hull cell capacity of 267 ml was used in the present study. In this cell, the
cathode is positioned at an inclined angle to the anode so that the current density at each
point on the cathode is different.
The optimum current density range for obtaining quality deposits from the
selected plating bath was determined using Hull cell [7]. The experiments help in
determining the nature of deposits that could be obtained at different current densities in a
single experiment. Mechanically polished and degreased Brass/MS cathodes of 10.2 x
7.0 x 0.2 cm area and copper, lead, and tin anodes of 6.5 x 6.5 x 0.5 cm size were used
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for the experiment. Before starting experiments the backside of the cathode panels were
masked using duroflex lacquer. The cathode panels were subjected to electrochemical
surface treatment using the following solutions.
Sodium carbonate 30 g/l
Sodium hydroxide 30 g/l
Anode Stainless steel
Current density 1.5 A/dm2, 4.5 A/dm2 (for brass)
Cathodic treatment 2 minutes
Anodic treatment 30 seconds.
Preliminary studies were carried out with Hull-cell using various electrolytes
under different conditions. After the experiments, the panels were washed, dried and the
results were expressed using codes to indicate the nature of deposits. By measuring the
distance from high current density and the distance of the points spanning the desired
deposit pattern, the value of current densities corresponding to those points and hence the
current density range for production of deposits of desired quality were determined. The
technique was also employed to identify a suitable addition agent that could be used to
improve the quality of deposits. The following formula enabled calculation of the current
density at a desired point on the Hull cell cathode.
Current density in A/dm2 at any point on the
inclined cathode = C (5.1-5.24logL)
Where C is the total current passing through the cell, ‘L’ is the distance in cm of
the point of interest from the nearer end of the cathode.
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All dimensions in mm
Figure 3.1 Cross section of Hull cell diagram
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3.3.3 Throwing power (Haring-Blum cell) [9]
Throwing power is regarded as one of the important characteristic properties of
any electroplating bath because it is a measure of the ability of the bath to cover the
surface or throw the metal uniformly over corners and in recesses. The throwing power
is commonly expressed as a percentage. After Field’s contribution to the plating scene,
the unit of percentage came to be expressed either as a positive (+ve) or a negative (-ve)
figure with 100 as the maximum. According to field the positive figures would represent
good performance of the baths and negative ones, their poor performance. He further
explained the poor performance in terms of non-uniform coverage and thickness of the
deposit.
It is a well-known fact that the alkaline baths are always associated with a high
(good) throwing power, probably because of the high over-potentials for metal deposition
is such solutions. In contrast, the throwing power is low or poor in the case of acid baths
due to low over-potentials.
The chief factors affecting throwing power are the extent to which the cathode
polarizes with increase in current density, the electrical conductivity of the electrolyte
and the relationship between cathode current efficiency and cathode current density.
The steeper the slope of the cathode polarization curve and greater the
conductivity of the electrolyte, the more uniform will be the current distribution and
hence the metal distribution over the cathode surface. If the cathode current efficiency
decreases with increase in current density, the uniformity of the metal distribution is
improved.
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Haring-Blum cell is used to determine throwing power. It is basically a
rectangular (15 x 5 x 5 cm) PVC box with an open top (Figure 3.2). Typically it has two
cathodes (5 x 5 x 0.2 cm) one at each end, with a single anode perforated of the same size
placed between them.
The studies on throwing power were carried out for different compositions of the
electrolytes of copper, lead, and tin under still and stirred conditions. Deposits were
produced on pre cleaned brass/steel cathodes, positioned at both ends of rectangular cell
with a distance ratio of 1:5 from the anode. The plating was carried out for 30 minutes at
1-10 A/dm2 for all the electrolytes. From the weight of the deposits obtained at the near
cathode (Cn) and far cathode (Cf) the throwing power was calculated. Under such
condition the electrolyte would behave in accordance with Ohm’s law and the metal
distribution would be proportional to the current distribution. In this hypothetical case
the current distribution is referred to as primary distribution. However, resistance at the
interface between the electrolyte and the cathode is high as compared with the resistance
of the electrolyte due to polarization and the resulting current distribution is known as
secondary distribution. Haring and Blum formula for determination of throwing power is
L-M Throwing power (%) = -------- x 100
L
In this expression C (Cn/Cf) is the metal distribution ratio, and K is the ratio of the
distance from the far cathode and the near cathode to the anode. Thus K is the current
distribution ratio and normally it is maintained at a value of 5. However, Field’s formula,
a modified term of Haring and Blum formula is the one greatly used, since the values it
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gives are more realistic and range from + 100 % to –100% irrespective of the value of K.
The Field’s formula is [10].
L-M Throwing power (%) = ---------- x 100
L+M – 2
Values of throwing power for different solutions were calculated with Field’s
formula.
3.4 Current efficiency
The studies on current efficiency and rate of build up were carried out for
different composition of the electrolytes under still and stirred condition. Experiments
were carried out in a 200 ml container containing 7.5(l) x 2.5 (b) x 0.5 (t) cm anodes
(copper, lead, tin,) with an exposed area of 2.5 (l) x 2.5 (b) cm and mild steel or brass
with exposed area of 2.5 (l) x 2.5 (b) cm by masking the unwanted portions by lacquer.
The cathodes were degreased and electrolytically cleaned in alkaline solution
prior to deposition. The specimens were weighed before and after deposition and the
cathodic current efficiency in each case was calculated using the relation
Weight of the deposit Cathode current efficiency = ------------------------- x 100 Theoretical weight
The theoretical amount of metal deposition was calculated using Faraday’s laws,
which states that gram equivalent weight of a metal deposited at the cathode requires
96,500 coulombs of electricity. The anodic dissolution efficiencies of copper, lead and tin
of above-mentioned dimensions were studied in their respective MSA baths and in
various concentration of pure MSA solution.
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The protective value of many electrodeposited coatings is determined mostly by
their thickness. It has been established that corrosion protection depends primarily on the
thickness or mass of the deposit [8]. In view of this, the thickness of the deposit and the
rate of deposition were calculated from the mass of the deposit obtained.
Mass of the deposit (gm) Thickness (micron) = --------------------------------- ----------- x 10 4
Density of the metal (g/cm3) x Area (cm 2)
3.5 Conductivity measurements
Solution of strong acids and bases are much better conductors than any other
aqueous solution and in electrolytic processes free acid or free alkali is often used to
improve the solution conductivity. It is very important that for an electroplating solution
being useful; conductivity should be adequate, avoiding the necessity of using higher
applied voltage and hence high energy-consumption.
Conductivity measurements were carried out for different compositions of the
electrolyte using Dot-tech digital conductivity meter (model Dot 466).
3.6 Polarization method
The cathodic polarizations were carried out in copper, lead, and tin electrolytes of
different compositions using three-electrode assembly under still and stirred condition.
Platinum foil of 1 cm2 area and saturated calomel electrode was used as the counter and
reference electrode respectively. Brass/steel of 1 cm2 area was used as a working
electrode. The anodic polarization of copper, lead, and tin, were also carried out in their
respective baths and in various concentration of pure MSA solution. Current steps were
applied using a constant current source and corresponding potentials were measured after
attaining steady state .
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Figure 3.2 Haring-Blum Throwing power cell
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3.7 Cyclic voltammetric studies
Potential sweep cyclic voltammetry is one of the most powerful electrochemical
techniques used as a means of obtaining a quick electrochemical spectrum of a charge
transfer system and also a method for the detailed examination of reaction mechanism. It
has also proved valuable in the study of surface processes, such as formation and
reduction of oxide layers on metal surfaces.
The electrochemical cell is made up of an all glass one-compartment cell with
three-electrode cell assembly.
For all the studies platinum foil of one square cm area was used as an auxiliary or
counter electrode (CE). The platinum disc electrode of specified area (0.003 cm2) was
used as a working electrode for copper and glassy carbon of specified area (0.196 cm2)
used as a working electrode for lead, tin systems. All the experiments were carried out
with saturated calomel electrode (Hg/HgCl2 filled with saturated potassium chloride) as a
reference electrode along with Agar-Agar-KCl salt bridge. The pretreatments of the
working electrode consisted of polishing with emery paper, degreasing using tri chloro
ethylene, washing and rinsing with distilled water.
For cyclic voltammetry experiments analytical grade chemicals and triple distilled
water were used for the preparation of solutions. The electrolytes were prepared by
mixing the appropriate solutions with stochiometric amounts of the reagents concerned.
The solution under study was deoxygenated for one hour using purified nitrogen.
The experimental arrangement consists of potentiostat (Wenking Model VSG 72)
and X-Y recorder (Rikadenki, Japan). The potential range for electrodeposition was
fixed after carrying out several experiments to get reproducible results in all the copper,
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lead, tin electrolytes. Cyclic voltammetry studies were carried out with various
electrolytes of the following compositions as given in the table 3.2
3.8 Corrosion resistance studies
One of the important properties of electrodeposited coatings is their corrosion
resistance. The porosity of electrodeposits is closely related to its corrosion behaviour.
Evaluation of corrosion resistance may be carried out by non-electrochemical and
electrochemical techniques. Corrosion data like corrosion current Icorr, corrosion potential
Ecorr and weight loss were found out using various techniques like potentiodynamic
polarization and weight loss method.
3.8.1 Potentiodynamic polarization method
The earlier work of Wagner and Traud showed that there is a linear relationship
between potential and applied current at potentials only slightly removed from the
corrosion potential. They considered this relationship to be especially important because
low current polarization measurements combined with corrosion rate data permit
calculation of Tafel slopes. Since the measurements are carried out close to the corrosion
potential, only surface changes resulting from high current polarization are eliminated.
The slope of the linear portion will give the polarization resistance Rp = ∆E/∆t in
ohm.cm-1. I corr can be calculated by knowing the anodic and cathodic slopes ba and bc
respectively using the following equation.
ba bc I corr = ---------------- 2.303 Rp (ba + bc)
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Table 3.2 Composition of baths used for cyclic voltammetry studies
Bath Constituents
A1 Copper (as methane sulphonate) 0.70- 0.10 M
MSA 0.31–0.73 M
Temperature RT (30oC)
B1 Copper (as copper sulphate) 0.70- 0.10 M
Sulfuric acid 0.31 - 0.73 M
Temperature RT (30oC)
C1 Lead (as methane sulphonate) 0.24 -0.48 M
MSA 0.21- 0.62 M
Peptone 1.0 g/l
Temperature RT (30oC)
D1 Lead (as fluoborate) 0.24- 0.48 M
Fluoboric acid 0.21- 0.62 M
Boric acid 0.48 M
Peptone 1 .0 g/l
Temperature RT (30oC)
E1 Tin (as methane sulphonate) 0.34 - 0.50 M
MSA 1.56 - 2.60 M
Peptone 1.0 g/l
Temperature RT (30oC)
F1 Tin (as fluoborate) 0.34- 0.50 M
Fluoboric acid 1.56 –2.60M
Boric acid 0.48 M
Peptone 1.0 g/l
Temperature RT (30oC)
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The corrosion resistance studies of electrodeposited copper, lead, and tin,
of various thickness obtained from various electrolytes were carried out with polarization
technique. A three-electrode cell assembly was used in these polarization studies. The
electrodeposited copper, lead, and tin specimens were masked with lacquer to expose
only one square centimeter area on one side of the working electrode. A platinum foil and
saturated calomel electrode were employed as auxiliary and reference electrodes
respectively. Polarization studies were carried out with 5 % W/V neutral sodium chloride
solution for testing using Auto lab Ecochemie BSTR 10A system. The potentials were
scanned at the rate of 5-mV/sec up to 200 mV from the OCP value both in the cathodic
and on the anodic direction with suitable IR corrections. The intercepts of the linear
portions of the two polarization curves give I corr and E corr values.
3.8.2 Electrochemical impedance measurement method
Using the three electrode cell assembly, as used in potentiodynamic polarization
method, impedance measurements were carried out on copper, lead and tin deposits in 5
% sodium chloride solution at OCP using Solartron Model SI 1280 B. A circuit diagram
for the impedance study is shown in figure 3.3. Impedance measurements were carried
out at the OCP of the working electrode using the AC impedance system. AC signal of
amplitude 10 mV was impressed to the system with the frequencies ranging from 10 KHz
to 1 mHz. The values of solution resistance (Rs) and charge transfer resistance (Rt) have
been obtained from the Nyquist plot of real part (Z’) Vs imaginary part (Z’’).
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Figure 3.3 Circuit diagram for AC impedance measurement
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3.8.3 Self corrosion (weight loss) method
The corrosion rates can be expressed as variation in the weight per unit surface
area and unit time of penetration of the corrosion process into the metallic material in unit
time.
Weight loss experiments were carried out for copper, lead and tin anodes in
various concentrations of MSA. The anode area of (6.25cm2) was exposed for 7 days and
the corrosion products were removed and loss in weight was calculated [11].
3.9 Properties of electrodeposits
The characteristics of deposits mainly depend upon the nature of metals and
alloys. Properties of the electrodeposits were studied by measuring adhesion, porosity,
hardness and solderability.
3.9.1 Adhesion
A number of qualitative and quantitative tests have been developed for adhesion.
The qualitative tests are (a) bend test (b) twist test (c) heat cycling (d) burnishing (e)
scratching and chisting (f) impact tests and cupping. The qualitative tests are (1) peel test
(2) tensile test and (3) shear test.
In the present work bend test has been used for qualitatively assessing the deposit
adhesion [12]. The bend test comprises bending of the plated object to such as extent as
the specimen will permit. The test piece is held firmly by vise and bent as sharply as
possible. The bending is frequently reversed and repeated unit basis metal is fractured.
Any evidence of peeling, flaking of the deposit is taken as cause of rejection.
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3.9.2 Porosity
Porosity of the electroplated metal coated over steel is detected by the Ferroxyl
test [13]. Special test papers were prepared by impregnating them in a solution containing
50 g/l sodium chloride solutions and then pressed against the electrodeposited panel and
left for 10 minutes. After removal the papers were immersed in a 10g/l solution of
potassium ferry cyanide. Blue marks developed in the paper in the region where steel is
exposed through discontinuities in the coating were counted by viewing the surface with
microscope. The porosity of the coating was expressed as the percentage of defective
area.
3.9.3 Micro hardness
The value of micro hardness of electrodeposits of copper, lead and tin obtained
from different electrolytes at different conditions were determined by using a HMV,
Shimadzu Micro hardness tester with a square base diamond pyramid, having an angle of
136o at the vertex between two opposite faces. The deposit should be of adequate
thickness so that the diamond pyramid does not penetrate it to a depth greater than 10 %
of its thickness. This can be readily ascertained since the penetration depth is equal to
1/7 of the indentation diagonal. For determining micro hardness of deposit, the diamond
pyramid was pressed into the deposit for 10 seconds and the indentation diagonal was
measured after the load was removed. The Vicker’s micro hardness of the deposit in
Kg/mm2 was determined in each case by using the formula
V = 1854 x P ------------ d2
Where P is the load applied in grams and d is the diagonal of the indent obtained
in micrometers.
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3.9.4 Solderability
In this method [14] fixed volume of solder was placed on the test specimen,
which was heated to 513 K on a hot plate. On heating the test specimen, the solder melt
and spread over the surface. Then the sample was cooled and the area of spread was
measured with a planimeter. Spread factor for a particular test surface is calculated by
using the equation.
D-H Percentage spread factor = ------- x 100
D
Where D- diameter of sphere having a volume equal to that of the solder used and
‘H’ is the height of the solder spot. If there is no effect from gravity, surface tension or
wetting of the solder, the solder drop will assume the shape of a sphere. As the
solderability increases the height of the solder spot decreases resulting in the increase of
the spread factor value.
3.10 Structural characterisation
3.10.1 X-ray diffraction studies
The copper, lead, and tin deposited samples obtained from various electrolytes
were subjected to x-ray diffraction studies using PAnalytical model X’per PRO to
identify the orientation. CuKα radiation was used.
3.10.2 Scanning Electron Microscopic studies
The morphology of the electrodeposits was examined under high magnification to
assess the grain size, deposit nature, heterogeneities and pores present in the deposits
using a scanning electron microscope. The scanning electron microscope that makes use
of reflected primary electrons and secondary electrons enables one to obtain information
from regions, which cannot be examined by other techniques. The plated specimens
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were cut into 1 X 1 Cm2 size and mounted suitably and examined under the microscope.
The SEM photographs were taken by using Hitachi model S-3000H l with an acceleration
voltage range of 20,000V and with the magnification range of 1000 and 2000.
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5. A.G.Gray, ‘Modern Electroplating’ New York (1953).
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