Mechanism investigation of zinc electrodeposition reaction based on numerical simulation

In zinc electrodeposition, deposit morphology and thickness uniformity are governed by the coupling of current distribution, ion transport, and interfacial reactions. In this study, a three-dimensional transient finite-element model was established using COMSOL Multiphysics based on the tertiary current distribution framework. The model coupled ionic transport, charge conservation, interfacial electrochemical reactions, and deposition-thickness evolution to analyze Zn2+ and H+ concentration fields, current distribution, and deposition behavior. Simulations were performed under different flow rates, anode–cathode spacings, acid–zinc ratios, and current densities. The results showed that 250 ml min−1, 20 mm spacing, an acid–zinc ratio of 3.4, and 600 A m−2 provided a preferred operating window by balancing Zn2+ supply, H+ accumulation, and zinc growth. Experimental observations agreed well with the simulation trends.