Finite Element Simulation and Experimental Validation of Nickel Coating Thickness Distribution in Electroplated FCCZ Lattice Structures

Metal electrodeposition on additively manufactured lattice structures enables the creation of functionally graded hybrid components with enhanced mechanical properties. However, predicting coating thickness distribution remains challenging due to complex current density fields in intricate geometries. This study develops and validates a finite element electrochemical simulation model for predicting coating thickness distribution in lattice structures using COMSOL Multiphysics 6.1. The model incorporates Butler–Volmer electrode kinetics, mass transport limitations, and the Laplace equation for current distribution. Experimental validation was performed using FCCZ lattice structures electrochemically coated with nickel for 24 h at 200 A/m2. CT scanning analysis revealed mean absolute errors of 5.25% between simulation and experiment after model calibration. The validated model successfully captures the exponential coating gradient from exposed edges to internal regions and provides a robust predictive tool for coating thickness distribution, which is essential for the effective design and optimization of electrochemically metallized lattice structures.