Apparatus and method for ionic liquid electroplating

Abstract

An electroplating apparatus includes a container containing plural portions and an ionic liquid plating solution that is capable of flowing therebetween. The plural portions include at least a first portion containing a counter electrode that includes coating donor material and a second portion that includes a workpiece. A porous scrubber separating the first and second portions has a plurality of metallic outer surfaces in contact with the ionic liquid plating solution. Coating, repair, and regeneration methods using an ionic liquid plating solution are also described.

1 . An electroplating apparatus comprising:
 a container containing plural portions and an ionic liquid plating solution that is capable of flowing therebetween;   the plural portions including:
 a first portion containing a counter electrode that includes coating donor material; a second portion that includes a workpiece; and 
   a porous scrubber separating the first and second portions and having a plurality of metallic outer surfaces in contact with the ionic liquid plating solution.   
     
     
         2 . The apparatus of  claim 1 , wherein the workpiece comprises a metallic component substrate selected from the group consisting of: aluminum, magnesium, chromium, nickel, molybdenum, iron, and alloys thereof. 
     
     
         3 . The apparatus of  claim 2 , wherein the metallic component substrate comprises an aluminum alloy selected from the group consisting of: AA 6061 alloy, AA 7075 alloy, and AA 2024 alloy 
     
     
         4 . The apparatus of  claim 1 , wherein the workpiece comprises a turbine engine component. 
     
     
         5 . The apparatus of  claim 1 , wherein the workpiece comprises an outer displacement layer. 
     
     
         6 . The apparatus of  claim 5 , wherein the outer displacement layer comprises a metal selected from: zinc, tin, copper, zirconium, cerium, and alloys thereof. 
     
     
         7 . The apparatus of  claim 5 , wherein the ionic liquid plating solution contains ionic byproducts of the outer displacement layer. 
     
     
         8 . The apparatus of  claim 5 , wherein the ionic liquid plating solution comprises an ionic liquid selected from: 1-ethyl-3-methylimidazolium chloride [EMIM][Cl]—AlCl 3 , 1-butyl-3-methylimidizolium chloride [BMIM][Cl]—AlCl 3 , and combinations thereof. 
     
     
         9 . The apparatus of  claim 1 , wherein the coating donor material comprises substantially pure aluminum. 
     
     
         10 . The apparatus of  claim 1 , wherein the porous scrubber comprises a metallic outer surface selected from: substantially pure aluminum or substantially pure magnesium. 
     
     
         11 . The electroplating apparatus of  claim 1 , further comprising:
 an agitator adapted to circulate the ionic liquid plating solution through the porous scrubber.   
     
     
         12 . A method for coating at least a first surface of a workpiece with a metallic coating, the method comprising:
 pretreating a first portion of the workpiece that includes the first surface;   electrolytically etching the first portion of the workpiece in an ionic liquid plating solution to expose at least a portion of the first surface, thereby (i) accumulating ionic byproducts in the ionic liquid plating solution and (ii) activating the exposed portion of the first surface;   electrodepositing the metallic coating onto the exposed portion of the first surface in the ionic liquid plating solution; and   fluidly communicating a portion of the ionic liquid plating solution through a porous scrubber, the scrubber having a plurality of metallic outer surfaces in contact with the ionic liquid plating solution to capture at least some of the accumulated ionic byproducts from the ionic liquid plating solution.   
     
     
         13 . The method of  claim 12 , wherein the pretreating step comprises:
 one or more of grit blasting, acid etching, desmutting, rinsing, and drying.   
     
     
         14 . The method of  claim 12 , wherein the workpiece comprises a metallic component substrate selected from the group consisting of: aluminum, magnesium, chromium, nickel, molybdenum, iron, and alloys thereof. 
     
     
         15 . The method of  claim 12 , wherein the electrolytically etching step is performed using the same ionic liquid plating solution as is used in the electrodepositing step. 
     
     
         16 . The method of  claim 12 , further comprising:
 prior to the electrolytically etching step, depositing a displacement layer onto a portion of a workpiece.   
     
     
         17 . The method of  claim 16 , wherein the electrolytically etching step comprises:
 electrolytically removing at least a portion of the displacement layer to expose the portion of the first surface.   
     
     
         18 . The method of  claim 16 , wherein the displacement layer comprises a metal selected from a group consisting of: zinc, tin, copper, zirconium, cerium, and alloys thereof. 
     
     
         19 . The method of  claim 18 , wherein the depositing step comprises:
 an immersion process including a zincating process.   
     
     
         20 . The method of  claim 12 , wherein the protective metallic coating comprises a substantially pure metal selected from the group consisting of: aluminum and magnesium.