Elsy2D, an Elsyca product with proven track record, is a unique and user-friendly 2D software program providing a platform for the simulation and optimization of the complete range of electrochemical processes:

 

• Electroplating
• Anodizing
• Electroforming & Electrowinning
• Electrochemical Machining & Etching & Electropolishing
• Cathodic Protection

 

based on 2D or axisymmetrical cross sections of the electrochemical cell configuration.

 

Elsy2D has been especially designed to enable fast optimization of current density and layer thickness distributions (uniform or selective). The user-friendly graphical interface allows easy and very straightforward investigation of electrochemical cell dimensions, anode shape & positioning, shielding/current thieves, electrical contacting, applied voltage or current, bath characteristics, etc. on the current density and layer thickness distributions over the electrodes.

 

Based upon your specific requirements, Elsy2D’s modular approach provides a customized solution with significant added value at a competitive price.

 

Click here to download the Elsy2D datasheet.

Elsy2D can be applied to a wide variety of processes in distinctive industries as for example:

 

• Decorative Chromium plating of parts for domestic appliances or car finishing parts
• Selective hard Chromium plating of engine parts
• Zinc plating of parts, sheets and wires for corrosion protection
• Wafer and lead frame plating (copper, gold, nickel etc.)
• Printed Circuit Board (PCB) plating
• Anodizing and electrocolouring of parts and sheets
• Electroforming of dies, grinding wheels, reflectors (nickel) or foils (e.g. copper)
• Electrowinning of metals
• Electrochemical machining (ECM) of cavities or holes, incisions
• Electrochemical drilling (ECD) of canals
• Electrochemical deburring
• Electropolishing or pickling of parts, sheets and wires
• Cathodic Protection of buried tanks or submerged structures (e.g. vessels)

Elsy2D benefits your electrochemical process business by providing:

 

• an in-depth insight and understanding of your electrochemical processes,
• enormous time and cost savings from the design to manufacturing phase,
• optimisation towards process yield, product quality (e.g. uniform electroplating thickness) and through-put.

 

When using the Elsy2D software, you can count on:

 

• detailed documentation,
• customised on-site training by the expert team of Elsyca,
• responsive technical support.

Elsy2D's basic program key features are:

 

• Two-dimensional and axi-symmetrical electrochemical cell configurations
• Easy data input: the cell configuration can be defined based on geometrical parameters, enabling easy modification
• Definition of electrode types, mass transfer limitations, imposed current or potential values are straightforward using the Elsy2D Input Wizard
• Automated meshing
• Fast solver: most configurations can be computed within a few minutes on a standard PC
• Vizualisation options: current density and layer thickness distributions along the electrodes; potential isolines and current density vectors over the electrolyte domain(s); electrode shape evolution over time for electroforming and ECM applications

 

Elsy2D's basic program solver features:

 

• Electrode polarisation & efficiency defined by linear or Butler-Volmer type relations, or through direct import from experimental data
• Electrodes with high internal resistivity
• Time dependent decrease of the internal electrode resistance
• Imposed potential on different electrodes
• Imposed current through one or a collection of electrodes (includes floating and bipolar electrode modeling)

 

The possibilities of Elsy2D can be extended with the following dedicated add-on modules for modeling specific phenomena and processes:

 

• Mass transfer limitations: enables modeling of the effect of inadequate electrolyte agitation or replenishment on metal-ion transport to the cathode for simple hydrodynamic cases (e.g. flat plate or parallel plates with parallel flow).
• Multiple regions with different electrical conductivities: for cells with an anolyte and catholyte region, and for cathodic protection applications.
• Reel-to-reel plating cells: dedicated software for very thin or resistive moving sheets and wires.
• Electrochemical machining shape change: enables computation of the anode shape change based on Faraday’s law for ECM applications and other processes where electrochemical dissolution occurs over a number of userdefined time steps.
• External electrical networks: required if either the electrical wiring or the external current (or potential) sources to multiple electrodes becomes rather complex. The add-on module takes into account the resistance of contacts, wires etc.
• Electrode growth shape change: allows computation of the cathode shape change based on Faraday’s law for electroforming applications over a number of user-defined time steps.
• Moving electrodes: for defining moving cathode tools that are either subject to a fixed speed or maintain a minimum distance to the product.
• Automated geometrical parameter optimisation: a powerful tool for optimisation, e.g. screens, current thieves, cathode and anode dimensions and positions, and product masking. The target can be a user-defined layer thickness distribution or a specific product shape (ECM and electroforming). The algorithm will determine the optimal set of geometrical dimensions within user-defined upper and lower bounds.

Operating system: Windows operating system (2000/NT/XP)

 

Internal memory: minimum 512 MB RAM or more recommended

 

Processor: minimum 1GHz or more recommended

Elsy2D requires basically the following input:

 

• geometry and dimensions of the reactor/cell/tank cross section
• definition of electrolyte conductivity
• definition of 1 or more electrode types with adequate polarization data
• assignment of electrode types to relevant line segments
• definition of a discretisation for the cell boundary lines
• definition of the imposed current or potential signal on connected electrodes
• process time

 

In case of mass transfer limitations, external electrical networks, moving electrodes, or reel-to-reel electrodes are defined, additional input is required.

 

Elsy2D output:

 

• graphical representation of current density and layer thickness distributions over all electrodes
• electrolyte potential distribution along the electrodes and in the electrolyte domain
• Excel .xls file containing all relevant quantities (current density, electrolyte potential, electrode potential, deposited or dissolved vectorial material rate) along the electrodes
• Excel .xls file containing global data (total current per electrode)
• TecPlot .plt containing all relevant scalar and vector fields in the electrolyte domain

 

For electroforming and electrode dissolution processes (ECM, electropolishing, etching), also the shape change profiles of the electrode(s) are available from both graphical representation in the Elsy2D user interface and the .xls files.

To view a larger image of the pictures, simply click on the picture.

 

Elsy2D interface

 

 

 

 

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Electroplating shape change for hard chromium layer deposition in a piston groove

 

 

 

 

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Electroplating current density distribution for hard chromium plating process in a piston groove

 

 

 

 

 

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Current density distribution over the right hand side piston groove wall (from bottom to top)

 

 

 

 

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Layer thickness distribution over the right hand side piston groove wall (from bottom to top)

Elsy2D has already proven its benefits several times:

 

“Elsy2D’s architecture is a well-considered concept with a logical structure, as a consequence, it is very user-friendly”

(Dr. Jacques Wijenberg, Corus Group - The Netherlands)

 

“The Elsy2D software has proven to be a valuable modelling tool to obtain better quality electrodeposits on our existing wire products. Moreover, it has facilitated an accelerated development of new electrolytic coating techniques for Bekaert such as the Cu-plating for flexible circuits. We clearly intend to continue using Elsyca’s software tools within Bekaert.

(Dr. Wim Vanvooren, Bekaert N.V. – Belgium)

 

“Elsy2D is a very powerful tool for our research work and we use it successfully for various applications in electrochemical plating processes.”

(Dr. rer. nat. Manfred Rössler and Dr. techn. Maximilian Staudacher, Robert Bosch GmbH - Germany)