Exploring Zinc-Nickel Thin Film Morphology and Thickness on Manufactured Surfaces

Thin films are important in many technologies, from electronics to protective coatings. The way these films grow can change depending on the shape of the surface they are deposited on. In this project, we studied how a ZnNi thin film deposited onto three different surfaces: a flat plate, bolts, and a screw. Using scanning electron microscopy (SEM), we examined the overhead surface morphology and measured film thickness through cross-sectional imaging. Energy dispersive X-ray spectroscopy (EDS) was also used to determine the chemical composition of the film. Comparing a cross-section of the flat plate to the deposition on more complex surfaces, we observed differences in how the thin film covered the surfaces and how its thickness varied. This study shows how surface geometry influences thin film growth and provides insights for improving thin film deposition on non-flat materials.