Electrodeposition with modulated currents in optics of a Circular Economy

This doctoral thesis investigates the application and optimization of pulsed current (PC) electrodeposition for decorative metallic coatings, with a focus on its industrial use in fashion and luxury sectors. The research was carried out in close collaboration with a galvanic company, providing access to real production environments and allowing the identification of current technological limitations and areas for innovation. While direct current (DC) deposition remains the industrial standard due to its simplicity, pulsed current offers superior control over coating microstructure, surface finish and functional performance. Its limited industrial adoption, however, stems from the complexity of process tuning and the lack of systematic studies bridging laboratory and large-scale production. This work addresses this gap through a comprehensive analysis of PC parameters and their influence on coating morphology, composition and properties. The study focuses on alkaline copper, acidic copper, palladium and gold – plating bath widely used in decorative electroplating - investigating how waveform modulation (frequency, duty cycle, amplitude) affects deposition kinetics and final film characteristics. A combination of electrochemical and surface characterization techniques was employed to correlate electrical parameters with coating performance. Results show that optimized PC conditions enhance uniformity, brightness and adhesion while reducing internal stress and porosity. In particular, palladium and gold coatings exhibited improved barrier properties and corrosion resistance, enabling a reduction in precious metal use without compromising decorative quality. Beyond technical improvements, this study advances sustainable electroplating practices, contributing to greener, more efficient manufacturing aligned with circular economy principles.