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The transition from laboratory-scale research to pilot-scale production is a crucial phase in developing nickel coating technologies. While these coatings are expected to provide excellent corrosion resistance, durability, and conductivity, their large-scale production and application must be assessed for sustainability, economic feasibility, and regulatory compliance. Ensuring sustainability during this transition is essential to minimize environmental impact, optimize costs, and meet regulatory standards.   A Life Cycle Assessment (LCA) evaluates the environmental footprint, focusing on raw material extraction, energy consumption, emissions, and waste management. Nickel production and electroplating are energy-intensive and generate hazardous by-products such as heavy metal waste and chemical effluents. Sustainable solutions, including closed-loop recycling, optimized plating baths, and eco-friendly alternatives, help mitigate these impacts. In addition, a Life Cycle Costing (LCC) Analysis assesses capital and operational costs, process efficiency, and market potential to ensure cost-effective scaling. Innovations such as low-energy deposition techniques and resource-efficient chemical formulations improve economic viability while...

Since the NICKEFFECT projects aims at replacing platinum catalyst based PEM Fuel Cell (FC) cathodes by porous graphite electrodes that are covered with nickel alloy (nano-)particles, the plating process for creating these nickel nuclei populations  must be properly understood and controlled.   Same as for Water Electrolysis (WE) cells, the use of porous electrodes allows creating a high surface to volume ratio.  The throwing power of a full coverage nickel alloy plating process into a porous structure as for example a carbon fiber cloth is limited (WE cathodes), and the same holds for a nucleation plating process into a porous carbon structure (FC cathodes).  But whereas the main specifications in case of a full coverage nickel alloy plating process for WE cathodes involve primarily the local plating layer thickness and alloy content, for FC cathodes practically all local characteristics of the nuclei population are of importance, involving nuclei density, nuclei size...