Theoretically based engineering correlations are developed for prediction of structure, scaling properties, and growth velocities far from equilibrium in electrochemical deposition. Structures and structural transitions are correlated with control parameters and are recorded with high-resolution photomacroscopy. The principles governing destabilization of an initially smooth growth front and its dynamic restabilization into a structured aggregate are formulated by analysis of the diffusion and electric fields with consideration of concentration, kinetic overpotential, and double-layer charging. Schlieren photography is used to image the diffusion field around growing aggregates. The role of the surface overpotential is probed using AC impedance measurements. The theory developed in this project and the control strategies derivative from it will have broad applicability whenever electrically induced aggregation is either necessary or detrimental. Test metals for the experimental verification are selected to be technologically relevant, so that the results should be immediately applicable in battery and microelectronic circuit production.
