Computer controlled multifunctional current source design and applications

Electrodeposition technique is one of the most economical methods used to produce metallic coatings for many years. The main goal in metal coating processes with the electrodeposition method is to achieve better results for material surfaces in matters such as wear, corrosion, high temperature resistance, and hardness. Direct Current (DC) is commonly used for the production of metal coatings by electrodeposition method. Recent studies have shown that in addition to the DC electrodeposition method, using Pulse Current (PC) and Pulse Reverse Current (PRC) electrodeposition methods and changes in the current waveform can positively affect the coating results. In this thesis, a new current source (current generator) system that can convert basic signals used in engineering to current waveforms for metal plating with electrodeposition method is designed. The current generator system has been implemented using power electronics circuit topologies, Buck Converter and H-Bridge. Artificial Neural Network (ANN), a non-linear algorithm, has been adapted to the hybrid power electronics system to generate predicted current waveforms. Later, coating experiments were carried out with electrodeposition method using a new generation current generator system. Copper (Cu) is used as cathode and Nickel (Ni) as anode in the coating process. Coating tests have been carried out for constant maximum current (Imax) conditions. The experiments were repeated with 3 different frequencies for each coating current signal. After coating, surface morphology and edge coating success of the coated areas were examined and the results were discussed by comparing with DC, PC and PRC methods.