Copper Cathode Contamination by Nickel in Copper Electrorefining

Nickel behavior has a significant role in the electrorefining of copper, and although it has been extensively studied from the anode and electrolyte point of view over the past decades, studies on nickel contamination at the cathode are limited. In the current paper, three possible contamination mechanisms—particle entrapment, electrolyte inclusions and co-electrodeposition—were investigated. Copper electrorefining (Cu-ER) was conducted at the laboratory scale, and the cathodes were analyzed by scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) and flame atomic absorption spectroscopy (AAS). Particle entrapment was studied by adding NiO and Fe2O3 to the system to simulate nickel anode slime, and the experiments were replicated with industrial anode slime material. The possibility of electrolyte entrapment due to nodulation was explored through the addition of graphite to produce nodules on the cathode. Co-electrodeposition was analyzed by experiments that utilized a Hull cell. The results indicate that particle entrapment can occur at the cathode and is a major source of the nickel contamination in Cu-ER, whereas nickel compounds were not shown to promote nodulation. Inclusions of bulk electrolytes within the surface matrix were observed, proving that electrolyte entrapment is possible. As co-electrodeposition of Ni in Cu-ER is thermodynamically unlikely, these experimental results also verify that it does not occur to any significant extent.

Particle entrapment in elliptical, elastohydrodynamic, rough contacts and the influence of intermolecular (van der Waals) forces

The entrapment/rejection process of spherical, rigid microparticles in elliptical, rough elastohydrodynamic contacts is modelled. An earlier model of the author is extended to include van der Waals intermolecular forces, in addition to mechanical (reaction and friction) and fluid–particle forces. Surface roughness effects are also introduced in terms of the intermolecular force formulation and in the microscale friction (particle–asperity) sub-model. Possibilities related to particle entry into a contact are quantified by weight factors and performance indices. A total entrapment index is defined and linked to the probability of particle entrapment. A parametric analysis investigates the effect of the intermolecular particle force on the entrapment probability by varying the contact load, lubricant viscosity, elastic modulus of the contacting solids, contact velocity and the macroscopic (Coulomb) coefficient of friction.

Particle Entrapment in Line Elastohydrodynamic Contacts and the Influence of Intermolecular (van der Waals) Forces

A metallic particle passing through concentrated rolling-sliding contacts is often linked to surface damage for particles larger than the available gap. At the instant of particle pinching, force balancing dictates particle entrapment and passing through the contact or rejection. It is vital to include all major forces in this process. This study revisits the analytical entrapment model previously published by the author for spherical micro-particles by incorporating a force so far overlooked in related studies, namely the van der Waals intermolecular force and, additionally, surface roughness effects. In conjunction with particle mechanical and fluid forces, this provides an almost complete set to use for correct force balancing. A parametric analysis shows the effect of several geometrical, mechanical, rheological, and surface parameters on spherical particle entrapment and reveals the significance of the van der Waals force for particles smaller than about 5–10 μm in diameter.

Hierarchically Combined Periodic SERS Active 3D Micro- and Nanostructures for High Sensitive Molecular Analysis

To increase the local field intensity of Raman scattering, gold nanospheres were entrapped in gold coated periodic inverse pyramid structures, being SERS substrates by themselves. The applicability of this complex structure for sensitive molecule detection was proved by comparison of the detected Raman signals with and without particle entrapment. Moreover its relevance in molecular diagnostic was also proposed considering the specific surface functionalisation of the gold nanoparticles.

Particle extrusion in elastohydrodynamic line contacts: Dynamic forces and energy consumption

The author’s model of particle entrapment and thermoviscoplastic indentation built and experimentally validated in recent publications is utilised to calculate the contact forces on ductile, isolated interference particles passing through elastohydrodynamic, rolling–sliding, line contacts. The model is detailed and enriched by supplementary equations. A parametric study deals with the effects of particle size and cold hardness, kinetic friction coefficient, rolling velocity and slide-to-roll ratio of the contact on the particle contact forces, mean friction coefficient, temperature, plastic work and power required to deform a particle, as well as on dent volume and plastic strain rates of the indented contact surfaces. A factual selection of optimal conditions and parameter values that minimise the disruption of a contaminated contact is thus greatly facilitated.