Apparatus and System Design, Build & Modeling
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Explore our Electrochemical Apparatus and System Design, Build and Modeling Approaches
Faraday designs systems and creates models to improve product performance, reduce downtime and improve reproducibility. The following examples demonstrate some of the Electrochemical Models we have developed with our multi-physics platform and Electrochemical Systems that we have designed and built for our customers.
Faraday installs custom flexibility into many of our systems allowing developers and users to enhance operational control to achieve consistent performance. We also use multi-physics modeling to improve tool designs, enabling more controlled operations. Finally, we design flow manifolds and bipolar plates for improved plate and frame operations.
These techniques have been proven to:
- Improve process uniformity
- Focus or de-focus the current density
- Enable rapid scale up of process and apparatus
- Control hydrodyanmic flow of the apparatus to enable improved process yield
Click tab to see examples, publications, patents and awards
- Apparatus & System Design and Installation
- Modeling
Plate and Frame Reactors
ECHANGE®

ElectroReactor®

Patents:
“Method of removing metal salts from solution by electrolysis an electrode closely associated with an ion exchange resin.” Chengdong Zhou, E. Jennings Taylor, Robert P. Renz, Eric C. Stortz, Jenny J. Sun
FARADAYIC® ElectroCell®
Patents:
“Electroplating cell with hydrodynamics facilitating more uniform deposition across a workpiece during plating.” Lawrence E. Gebhart, Jenny J. Sun, Phillip O. Miller, E. Jennings Taylor
“Method of operating an electroplating cell with hydrodynamics facilitating more uniform deposition on a workpiece with through holes.” Lawrence E. Gebhart, E. Jennings Taylor
“Electroplating cell with hydrodynamics facilitating more uniform deposition on a workpiece with through holes during plating” Lawrence E. Gebhart, E. Jennings Taylor
“Electroplating cell with hydrodynamics facilitating more uniform deposition across a workpiece during plating” Lawrence E. Gebhart, Jenny J. Sun, Phillip O. Miller, E. Jennings Taylor
Bench-Scale


Alpha- to Beta-Scale


Full Commercial Scale


Specialty Systems

Electrochemical Winning
Faraday designed and built a large working area electrochemical winning system to remove waste metals from plating, electrochemical machining, and pickling operations. This process reduced waste and improved the lifetime of the working solutions for their given applications.
Patents:
“Electroplating cell with hydrodynamics facilitating more uniform deposition across a workpiece during plating” Lawrence E. Gebhart, Jenny J. Sun, Phillip O. Miller, E. Jennings Taylor
“Electroplating cell with hydrodynamics facilitating more uniform deposition on a workpiece with through holes during plating” Lawrence E. Gebhart, E. Jennings Taylor
Reel to Reel Wire Polishing
Faraday designed and built a continuous feed reel-to-reel system to electropolish wire. This system is installed at Faraday and features controllable:
- Wire processing length
- Anode area
- Drying and rinse station
- Loadable hardware

Nb Superconducting Radio Frequency Cavities
Faraday has scaled their Nb superconducting RF cavity electropolishing approach from single to nine-cell 1.3 GHz cavities as well as three-cell 805 MHz cavities.

KEK 9 - Cell Nb Superconducting Cavity Polishing

ORNL 3 - Cell Nb Superconducting Cavity Polishing
Electrochemical Modeling
Surface Finishing
- Predict Electroplating Uniformity with Primary/Secondary/Tertiary Current Distribution
- Improve Coating Quality and Process Control

Modeling Current Flow/Voltage Drops in an Anode Bussing Frame
Electrochemical Machining (ECM)
- Predict Part Geometry with Electrodissolution Kinetics
- Incorporate Fluid Flow Effects with Computational Fluid Dynamics (CFD)

Time-Varying 3D ECM Part Shape Predictions
Corrosion
- Corrosion Rate Predictions for General/Localized Corrosion Phenomena
- Galvanic Corrosion Simulation
- Cathodic Protection System Design

Corrosion Current Density Predictions for a Galvanic Fastener System
Faraday's Process Advantage
- Pulse/Pulse-Reverse Control of Electric Fields Provides Unique Advantages for Electrochemical Processes
- Models of the Pulse/Pulse-Reverse Can Predict Process Control Parameters
Model of Pulse Plating vs DC

Pulse Plating
