Abstract
Electroless nickel-based coatings are frequently used in the field of coatings to improve the surface properties of materials such as wear, hardness, and corrosion. In this study, Ni-W-P alloy and Ni-W-P/Al2O3 composites were coated on the aluminum substrate by electroless technique. Composite coatings were carried out after suspending process of alumina (Al2O3) particles at different concentrations in the electroless bath. The characterizations of the coatings were studied to be able to reach optimum particle concentration. Aluminum oxide particles (average particle size 300 nm) with different concentrations (5, 10, 15, 20 g/L) were added to the bath to determine the concentration effect. Scanning electron microscope (SEM) and field emission scanning electron microscopy (FESEM) analyses were performed to examine the microstructure images of the composite coatings. x-ray diffraction (XRD) analysis was performed to determine the coating layers' phase structures. The hardness of the coatings was determined by applying the hardness test on a microscopic scale. CSM tribometer was used to establish the wear and friction properties of the coatings. Galvanometer was used to determine corrosion resistance. After the studies, hardness values of coatings were successfully increased from 552 to 700 HV depending on the amount of particles in the coating layer. The friction coefficient was also improved by decreasing that from 0.45 to 0.1 µ grades with the contribution of Al2O3 particle reinforcement to Ni-W-P coating. The wear rate of the coatings decreased from 5.96 × 10 −5 to 3.16 × 10−5 mm3/Nm\()\) with the increase of Al2O3 particles in the composite coating which indicates approximately two times improvement in the wear resistance. The corrosion resistance of composite coatings also increased, and an improvement in corrosion rate was achieved from 392 value to 063µm/year value with increasing particle concentration.
Similar content being viewed by others
References
A. Brenner and G.E. Riddell, Nickel Plating on Steel by Chemical Reduction, Plat. Surf. Finish., 1998, 85(8), p 54–56. https://doi.org/10.6028/jres.037.019
H. Harada, Electroless Plating: Fundamentals and Applications, Journal of the Japan Society of Colour Material, 1996, 69(1), p 60–70. https://doi.org/10.4011/shikizai1937.69.60
C.R. Shipley, Historical Highlights of Electroless Plating, Plat. Surf. Finish., 1984, 82(9), p 13–24.
P. Sahoo and S.K. Das, Tribology of Electroless Nickel Coatings–A review, Mater. Des., 2011, 32(4), p 1760–1775. https://doi.org/10.1016/j.matdes.2010.11.013
P. Biswas, S.K. Das, and P. Sahoo, Role of Heat Treatment on the Friction and Wear Behavior of Duplex Electroless Nickel Deposits, Mater. Today Proc., 2022, 66, p 3902–3909. https://doi.org/10.1016/J.MATPR.2022.06.322
P. Biswas, S.K. Das, and P. Sahoo, Duplex Electroless Ni-P/Ni-P-W Coatings: Effect of Heat Treatment on Tribological and Corrosion Performance, Mater. Today Proc., 2022, 66, p 2237–2244. https://doi.org/10.1016/J.MATPR.2022.06.042
J. Flagel, “Top 10 Uses of Aluminium in the Industry Today,” Matmatch, 2020. https://matmatch.com/blog/top-10-uses-of-aluminium-in-the-industry-today/ (Accessed Sep. 26, 2021)
J. Zang, S. Yu, G. Zhu, and X. Zhou, Fabrication of Superhydrophobic Surface on Aluminum Alloy 6061 by a Facile and Effective Anodic Oxidation Method, Surf Coat Technol, 2019, 380, p 125078. https://doi.org/10.1016/J.SURFCOAT.2019.125078
S.K. Das and P. Sahoo, Electroless Nickel-Phosphorus Deposits, Electroless Nickel Plating. CRC Press, 2019
W. Li, H. Liao, and H. Wang, “Cold Spraying of Light Alloys, Surface Engineering of Light Alloys: Aluminium, Magnesium and Titanium Alloys. Elsevier, 2010, p 242–293
F. Nassoy et al., Growth of Vertically Aligned Carbon Nanotubes on Aluminium Substrate Through a One-Step Thermal CVD Process, Nanotechnology, 2019, 8(61), p 9–16.
S. Tan, H. Algül, E. Kiliçaslan, A. Alp, H. Akbulut, and M. Uysal, The Effect of Ultrasonic Power on High Temperature Wear and Corrosion Resistance for Ni Based Alloy Composite Coatings, Colloids Surf. A Physicochem. Eng. Asp, 2023, 656, p 130345. https://doi.org/10.1016/J.COLSURFA.2022.130345
S.H. Hashemi and A. Ashrafi, Characterisations of Low Phosphorus Electroless Ni and Composite Electroless Ni-P-SiC Coatings on A356 Aluminium Alloy, Trans. Inst. Met. Finish., 2018, 96(1), p 52–56. https://doi.org/10.1080/00202967.2018.1403161
Y. Wang et al., Influence of Pretreatments on Physicochemical Properties of Ni-P Coatings Electrodeposited on Aluminum Alloy, Mater Des, 2021, 197, p 109233. https://doi.org/10.1016/J.MATDES.2020.109233
A. Warshawsky, C.L. Voycheck, W.T. Ferrar, and D.F. O’Brien, Metalization of Lipid Vesicles via Electroless Plating, J Am Chem Soc, 1988, 110(1), p 288–289. https://doi.org/10.1021/ja00209a046
X.M. Chen, G.Y. Li, and J.S. Lian, Deposition of Electroless Ni-P/Ni-W-P Duplex Coatings on AZ91D Magnesium Alloy, Trans. Nonferrous Metals Soc. China, 2008, 18, p s323–s328. https://doi.org/10.1016/s1003-6326(10)60225-7
G. Lu and G. Zangari, Study of the Electroless Deposition Process of Ni-P-Based Ternary Alloys, J. Electrochem. Soc., 2003, 150(11), p C777. https://doi.org/10.1149/1.1614799
A. Biswas, S.K. Das, and P. Sahoo, Investigation of the Tribological Behavior of Electroless Ni-W-P Coating Pre and Post Phase Transformation Regime, Mater. Res. Express, 2019, 6(9), p 0965c1. https://doi.org/10.1088/2053-1591/AB33BD
K.H. Krishnan, S. John, K.N. Srinivasan, J. Praveen, M. Ganesan, and P.M. Kavimani, An Overall Aspect of Electroless Ni-P Depositions–A Review Article, Metall. Mater. Trans. A Phys. Metall. Mater. Sci., 2006, 37(6), p 1917–1926. https://doi.org/10.1007/s11661-006-0134-7
H. Liu, H.L. Yao, G.E. Thompson, Z. Liu, and G. Harrison, Correlation Between Structure and Properties of Annealed Electroless Ni-W-P Coatings, Surf. Eng., 2015, 31(6), p 412–419. https://doi.org/10.1179/1743294414Y.0000000422
A. Mukhopadhyay and S. Sahoo, A Grey-Fuzzy Based Approach for the Optimization of Corrosion Resistance of Rebars Coated with Ternary Electroless Nickel Coatings, J. Soft Comput. Civ. Eng., 2022, 6(2), p 107–127. https://doi.org/10.22115/SCCE.2022.326903.1401
A. Mukhopadhyay and S. Sahoo, Improving Corrosion Resistance of Reinforcement Steel Rebars Exposed to Sulphate Attack by the Use of Electroless Nickel Coatings, Eur. J. Environ. Civ. Eng., 2021, 26(11), p 5180–5195. https://doi.org/10.1080/19648189.2021.1886177
W. Wang, X. Jü, C. Xu, W. Zhang, N. Mitsuzaki, and Z. Chen, Study on Electroless Plating Ni-W-P Ternary Alloy with High Tungsten from Compound Complexant Bath, J. Mater. Eng. Perform., 2020, 29(12), p 8213–8220. https://doi.org/10.1007/S11665-020-05312-9
M. Uysal, Electroless Codeposition of Ni-P Composite Coatings: Effects of Graphene and TiO2 on the Morphology, Corrosion, and Tribological Properties, Metall. Mater. Trans. A, 2019, 50(5), p 2331–2341. https://doi.org/10.1007/S11661-019-05161-9
I.R. Mafi and C. Dehghanian, Studying the Effects of the Addition of TiN Nanoparticles to Ni-P Electroless Coatings, Appl. Surf. Sci., 2011, 258(5), p 1876–1880. https://doi.org/10.1016/j.apsusc.2011.10.095
T.R. Tamilarasan, R. Rajendran, G. Rajagopal, and J. Sudagar, Effect of Surfactants on the Coating Properties and Corrosion Behaviour of Ni-P-Nano-TiO2 Coatings, Surf. Coat. Technol., 2015, 276, p 320–326. https://doi.org/10.1016/j.surfcoat.2015.07.008
Q. Zhao and Y. Liu, Electroless Ni-Cu-P-PTFE Composite Coatings and their Anticorrosion Properties, Surf. Coat. Technol., 2005, 200(7), p 2510–2514. https://doi.org/10.1016/J.SURFCOAT.2004.06.011
T.C. Chou, T.G. Nieh, S.D. McAdams, and G.M. Pharr, Microstructures and Mechanical Properties of Thin Films of Aluminum Oxide, Scripta Metall. Mater., 1991, 25(10), p 2203–2208. https://doi.org/10.1016/0956-716X(91)90001-H
H. Gül, F. Kiliç, S. Aslan, A. Alp, and H. Akbulut, Characteristics of Electro-Co-Deposited Ni–Al2O3 Nano-Particle Reinforced Metal Matrix Composite (MMC) Coatings, Wear, 2009, 267(5–8), p 976–990. https://doi.org/10.1016/J.WEAR.2008.12.022
S. Alirezaei, S.M. Monirvaghefi, M. Salehi, and A. Saatchi, Wear Behavior of Ni–P and Ni–P–Al2O3 Electroless Coatings, Wear, 2007, 262(7–8), p 978–985. https://doi.org/10.1016/J.WEAR.2006.10.013
D. Mohanty, T.K. Barman, and P. Sahoo, Effect of İncorporation of Nano-Alumina on Tribo-Mechanical Behavior of Electroless Ni-B Coatings, J. Tribol., 2021, 30, p 24–43.
D. Mohanty, T.K. Barman, and P. Sahoo, “Effect of Nano Alumina Reinforcements on the Tribological Behavior of Electroless Nickel-Phosphorus Coatings,” Lecture Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-19-3266-3_17/COVER.
Ş Ürdem, E. Duru, H. Algül, M. Uysal, and H. Akbulut, Evaluation of High Temperature Tribological Behavior of Electroless Deposited NiB–Al2O3 Coating, Wear, 2021, 482–483, p 203960. https://doi.org/10.1016/J.WEAR.2021.203960
H. Simunkova, P. Pessenda-Garcia, J. Wosik, P. Angerer, H. Kronberger, and G.E. Nauer, The Fundamentals of Nano- and Submicro-Scaled Ceramic Particles İncorporation into Electrodeposited Nickel Layers: Zeta Potential Measurements, Surf. Coat. Technol., 2009, 203(13), p 1806–1814. https://doi.org/10.1016/J.SURFCOAT.2008.12.031
K. Murakami, M. Hino, M. Ushio, D. Yokomizo, and T. Kanadani, Formation of Zincate Films on Binary Aluminum Alloys and Adhesion of Electroless Nickel-Phosphorus Plated Films, Mater. Trans., 2013, 54(2), p 199–206. https://doi.org/10.2320/MATERTRANS.L-M2012830
T. Note, “Zeta potential: An Introduction in 30 minutes,” Zetasizer Nano Serles Technical Note. MRK654–01, 2011, 2,1–6
R. Hu et al., Deposition Process and Properties of Electroless Ni-P-Al2O3 Composite Coatings on Magnesium Alloy, Nanoscale Res. Lett., 2018, 13(1), p 1–8. https://doi.org/10.1186/S11671-018-2608-0/FIGURES/7
T. Radu, M. Vlad, T. Radu, M. Vlad, F. Potecaşu, and G.G. Istrate, Preparation and Characterization of Electroless Ni-P-Al2O3 Nanocomposite Coatings Investigation of Advanced Functional Materials using Atomic and Nuclear Analytical Techniques and İmaging Microscopy View Project Preparatıon And Characterızatıon of Electroless Ni-P-Al2O3 Nanocomposıte Coatıngs, Digest J. Nanomater. Biostruct., 2015, 10(3), p 1055–1065.
A. Akyol, H. Algul, M. Uysal, H. Akbulut, and A. Alp, A Novel Approach for Wear and Corrosion Resistance in the Electroless Ni-P-W Alloy with CNFs Co-Depositions, Appl Surf Sci, 2018, 453, p 482–492. https://doi.org/10.1016/J.APSUSC.2018.05.152
D. Liu, Y. Yan, K. Lee, and J. Yu, Effect of Surfactant on the Alumina Dispersion and Corrosion Behavior of Electroless Ni<span class=’icomoon’>?</span>P<span class=’icomoon’>?</span>Al2O3 Composite Coatings, Mater. Corros., 2009, 60(9), p 690–694. https://doi.org/10.1002/MACO.200805170
F. Kiliç, H. Gül, S. Aslan, A. Alp, and H. Akbulut, Effect of CTAB Concentration in the Electrolyte on the Tribological Properties of Nanoparticle SiC Reinforced Ni Metal Matrix Composite (MMC) Coatings Produced by Electrodeposition, Colloids Surf. A Physicochem. Eng. Asp, 2013, 419, p 53–60. https://doi.org/10.1016/J.COLSURFA.2012.11.048
H. Gül, M. Uysal, H. Akbulut, and A. Alp, Effect of PC Electrodeposition on the Structure and Tribological Behavior of Ni-Al2O3 Nanocomposite Coatings, Surf. Coat. Technol., 2014, 258, p 1202–1211. https://doi.org/10.1016/J.SURFCOAT.2014.07.002
M.U. Rana et al., Measurement of Exchange İnteraction in Ti-Substituted Ni-Ferrites, Solid State Commun., 2001, 121(1), p 51–54. https://doi.org/10.1016/S0038-1098(01)00442-2
A.L. Patterson, The Scherrer Formula for X-Ray Particle Size Determination, Phys. Rev., 1939, 56(10), p 978. https://doi.org/10.1103/PhysRev.56.978
S. Alirezaei, S.M. Monirvaghefi, M. Salehi, and A. Saatchi, Effect of Alumina Content on Surface Morphology and Hardness of Ni-P-Al2O3(α) Electroless Composite Coatings, Surf. Coat. Technol., 2004, 184(2–3), p 170–175. https://doi.org/10.1016/J.SURFCOAT.2003.11.013
G. Wu, N. Li, D. Zhou, and K. Mitsuo, Electrodeposited Co-Ni-Al2O3 Composite Coatings, Surf. Coat. Technol., 2004, 176(2), p 157–164. https://doi.org/10.1016/S0257-8972(03)00739-4
G.P. Ram, S. Karthikeyan, P.E. Nicholas, and A.S. Sofia, Dry Sliding Wear Behavior of Electroless NIP and NIP-Al2O3 Composite Coatings, Mater. Today Proc., 2021, 37(2), p 2001–2009. https://doi.org/10.1016/J.MATPR.2020.07.495
T. Yokobori, Physics of strength and plasticity, M.I.T. Press, Cambridge, 1969.
D.A. Smith, Wear and Friction Analysis of Thin Coatings, Silcotek 112 Benner Circle Bellefonte, PA 16823
F. Delaunois and P. Lienard, Heat Treatments for Electroless Nickel-Boron Plating on Aluminium Alloys, Surf. Coat. Technol., 2002, 160(2–3), p 239–248. https://doi.org/10.1016/S0257-8972(02)00415-2
F. Delaunois, J.P. Petitjean, P. Lienard, and M. Jacob-Duliere, Autocatalytic Electroless Nickel-Boron Plating on Light Alloys, Surf. Coat. Technol., 2000, 124(2–3), p 201–209. https://doi.org/10.1016/S0257-8972(99)00621-0
J. Sudagar, J. Lian, and W. Sha, Electroless Nickel, Alloy, Composite and Nano Coatings–A Critical Review, J. Alloys Compd., 2013, 571, p 183–204. https://doi.org/10.1016/j.jallcom.2013.03.107
F.H. Stott, The Role of Oxidation in the Wear of Alloys, Tribol Int, 1998, 31(1–3), p 61–71. https://doi.org/10.1016/S0301-679X(98)00008-5
S. Qi, X. Li, and H. Dong, Reduced Friction and Wear of Electro-Brush Plated Nickel Composite Coatings Reinforced by Graphene Oxide, Wear, 2019, 426–427, p 228–238. https://doi.org/10.1016/J.WEAR.2018.12.069
M. Uysal, H. Algül, E. Duru, Y. Kahraman, A. Alp, and H. Akbulut, Tribological Properties of Ni–W–TiO2–GO Composites Produced by Ultrasonically-Assisted Pulse Electro Co–Deposition, Surf. Coat. Technol., 2021, 410, p 126942. https://doi.org/10.1016/J.SURFCOAT.2021.126942
J.D. Yong, B.H. Koo, H.I. Hawang, S.K. Seo, and J.K. Park, Effect of Ultrasonic Process of Electroless Ni-P-Al2O3 Composite Coatings, J. Korean Inst. Surf. Eng., 2021, 54(6), p 315–323. https://doi.org/10.5695/JKISE.2021.54.6.315
Q. Feng et al., Investigation on the Corrosion and Oxidation Resistance of Ni–Al2O3 Nano-Composite Coatings Prepared by Sediment Co-Deposition, Surf. Coat. Technol., 2008, 202(17), p 4137–4144. https://doi.org/10.1016/J.SURFCOAT.2008.03.001
S. Dehgahi, R. Amini, and M. Alizadeh, Corrosion, Passivation and Wear Behaviors of Electrodeposited Ni–Al2O3–SiC Nano-Composite Coatings, Surf. Coat. Technol., 2016, 304, p 502–511. https://doi.org/10.1016/J.SURFCOAT.2016.07.007
Acknowledgments
We would like to thank Sakarya University of Applied Sciences Scientific Research Projects (BAP) Coordinatorship (Project No: 2021-01-05-052) for the financially supporting this study.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Gul, H., Usta, İ. Effect of Alumina Concentration on Morphology, Wear, and Corrosion: Electroless Ni-W-P/Al2O3 Composite Coatings on Aluminum Surfaces. J. of Materi Eng and Perform 32, 6107–6122 (2023). https://doi.org/10.1007/s11665-023-08184-x
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-023-08184-x