Effect of ultrasonic-assisted electroless plating on Ni-P Alloy coating internal porosity

This study investigates the optimization of ultrasonic-assisted electroless plating to address the issue of high internal porosity in Ni-P Alloy coatings which deposited on X-ray mirror molds. By refining ultrasonic processing parameters, we successfully produced electroless plating layers that meet stringent performance requirements. Experimental results demonstrate that employing an ultrasonic frequency of 40 kHz and an acoustic intensity of 350 W/m significantly reduces porosity, with internal voids accounting for only 0.03% of the total coating volumea marked improvement over conventional electroless plating. Additionally, the maximum observed pore radius was limited to 9.8 m, satisfying the specifications for Ni-P alloy coatings on small-scale X-ray mirror molds.