Dual Bath Electrodeposition of Alternate Multilayer Coatings of Zinc and Nickel Deposits

The synthesis of zinc and nickel alternate multilayer coatings produced by successive deposition from dual baths containing a revised zinc sulphate electrolyte and a new developed nickel bath has been investigated. Smooth and uniform zinc-nickel compositionally modulated multilayered (CMM) coatings with different multilayer configurations were obtained. The surface and cross-sectional morphologies of samples were examined using scanning electron microscopy (SEM). Cross-sectional morphology showed the layered structure of the coatings clearly.

Surface Modification With Zinc and Zn-Ni Alloy Compositionally Modulated Multilayer Coatings

Zinc and Zn-Ni alloy compositionally modulated multilayer （CMM） coatings were electrodeposited on to a steel substrate by the successive deposition of zinc and Zn-Ni alloy sublayers from dual baths. The coated samples were evaluated in terms of the surface appearance, surface and cross-sectional morphologies, as well as corrosion resistance. The microstructural characteristics that were examined using the field emission gun scanning electron microscopy （FEGSEM） confirmed the layered structure, grain refinement of the zinc and Zn-Ni alloy CMM coatings, and revealed the existence of microcracks caused by the internal stress in the thick Zn-Ni alloy sublayers. The corrosion resistance that was evaluated by means of the salt spray test shows that the zinc and Zn-Ni alloy CMM coatings were more corrosion-resistant than the monolithic coatings of zinc or Zn-Ni alloy of the same thickness. The possible reasons for the better protective performance of Zn-Ni/Zn CMM coatings were given on the basis of the analysis on the micrographic features of zinc and Zn-Ni alloy CMM eoatings after the corrosion test. A probable corrosion mechanism of zinc and Zn-Ni alloy CMM coatings was also proposed.

Corrosion behaviors of zinc and Zn-Ni alloy compositionally modulated multilayer coatings

Zinc and Zn-Ni alloy compositionally modulated multilayer （CMM） coatings were electrodeposited from dual baths. The coated samples were evaluated in terms of surface appearance, surface and cross-sectional morphologies, as well as corrosion resistance. The results obtained from the salt spray test show that the zinc and Zn-Ni alloy CMM coatings are more corrosion-resistant than the monolithic coatings of zinc or Zn-Ni alloy alone with a similar thickness. The corrosion potential measurement and anodic polarisation tests were undertaken to examine the probable corrosion mechanisms of zinc and Zn-Ni alloy CMM coatings. Analysis on the micrographic features of zinc and Zn-Ni alloy CMM coatings after the corrosion test explains the probable reasons why the Zn-Ni/Zn CMM coatings have a better protective performance. Surface morphologies and compositional analysis of the remaining coating material of Zn-Ni alloy deposit after the corrosion test confirms the dezincification mechanism of the Zn-Ni alloy deposit during the corrosion process.

Microstructure and properties of nanocrystalline nickel coatings prepared by pulse jet electrodeposition

The fabrication of nanocrystalline nickel coatings was conducted by pulse jet electrodeposition on the substrate of 45# carbon steel.The effects of average current density on the surface morphology,microstructure,average grain size and microhardness of nickel coatings were investigated by scanning electron microscopy(SEM),X-ray diffractometry(XRD)and microhardness measurement.In addition,the corrosion resistances of coating and substrate were compared.It is revealed that the nickel coatings prepared by pulse jet electrodeposition exhibit a fine-grained structure with a smooth surface and a high density,although some pores and defects are still present in coatings.With the increase of average current density,the average grain size of nickel coatings is reduced at first and then increased.The coating with the optimum compactness,the smallest average grain size(13.7 nm)and the highest microhardness are obtained at current density of 39.8 A/dm2.The corrosion resistance is obviously increased for the coatings prepared by pulse jet electrodeposition;however,the corrosion rate is increased after a certain period due to the penetration of the corrosive media.

Electrodeposition of Compositionally Modulated Zinc-cobalt Alloy Multilayer Coatings

The effects of pulse parameters on the cobalt content, surface morphologies and grain size of Zn-Co alloy deposits were studied using a pulse plating technique with a square-wave current containing reverse pulse. Average current density and reverse anodic current density amongst the variables investigated have very strong effects on the cobalt content in the Zn-Co alloy deposits. Grain size, surface appearance and internal stress in the deposit were improved significantly by introducing the reverse current. Varieties of Zn-Co alloy compositionally modulated multilayer (CMM) coatings with large differences in cobalt contents for different sublayers were electrodeposited by designing corresponding waveforms using a computer-aided pulse plater and characterized in terms of surface morphologies. Cross-sectional morphologies of the Zn-Co alloy CMM coatings, examined using field emission gun scanning electron microscopy (FEGSEM), confirmed the layered structure.

Characterization and optimization of pulse electrodeposition of Ni/nano-Al_2O_3 composite coatings

Nickel/nano-A1203 composite coatings produced by the pulse electrodeposition method and the influence of pulse parameters, i.e., pulse frequency, duty cycle, and current density on the microstructure, hardness, and corrosion resistance, were critically investigated on an AISI 1018 mild steel specimen electroplated in a Watt＇s type bath. The experiments were carried out with different combinations of pulse parameters using Taguchi＇s L27 orthogonal array, and 27 trials were conducted to study the effect of pulse parameters in view to maximize the hardness of the specimen. The assessment results clearly reveal that the specimen exhibits the maximum hardness at the pulse frequency of 20 Hz, duty cycle of 30%, and peak current density of 0.4 A/cm2, which are designated as the optimal parameters herein. Furthermore, the influences of those optimized pulse parameters over the microstructure and corrosion resistance were investigated, and some conclusions were drawn. Also, from the ANOVA examination, it is clear that duty cycle is predominant in affecting the hardness, while current density has relatively low impact.

Effect of tension deformation on microstructure and mechanism of electrodeposited nickel coating

Nickel coating deposits with better ductility on a lower carbon steel sheet were produced by electrodeposition method and the electrodeposited nickel coating was deformed with the strain of 10%. Then the surface morphology,the deformation texture and the mechanical properties were analyzed by scanning electron microscopy(SEM),X-ray diffractometry(XRD) and nano-indentation measurement,respectively. The principle of nano-indentation to measure the hardness and elastic modulus of nickel coating was introduced. The relation curves of the load and displacement were obtained,including the original electrodeposited samples and the samples under tension. The results show that:1) there are only two main texture components Ni(111) and Ni(200) in the nickel coating,and no new texture component is found due to the elongation;2) after tensile deformation in the coating,the surface roughness increases and the microcrack is found;3) The hardness and the elastic modulus decrease after tensile deformation;and 4) for the original electrodeposited sample,the indentation depths change with the load,the hardness and the elastic modulus decrease with the increase of the depth. In addition,the investigation of creep shows that the value of creep increases when the tensile strain ε>10%.

Preparation and tribological performance of electrodeposited Ni-TiB_2-Dy_2O_3 composite coatings

TiB2 and Dy2O3 were used as codeposited particles in the preparation of Ni-TiB2-Dy2O3 composite coatings to improve its performance. Ni-TiB2-Dy2O3 composite coatings were prepared by electrodeposition method with a nickel cetyltrimethylammonium bromide and hexadecylpyridinium bromide solution containing TiB2 and Dy2O3 particles. The content of codeposited TiB2 and Dy2O3 in the composite coatings was controlled by adding TiB2 and Dy2O3 particles of different concentrations into the solution, respectively. The effects of TiB2 and Dy2O3 content on microhardness, wear mass loss and friction coefficients of composite coatings were investigated. The composite coatings were characterized by X-ray diffraction （XRD）, inductively coupled plasma-atomic emission spectrometer （ICP-AES） and scanning electron microscopy （SEM） techniques. Ni-TiBE-Dy2O3 composite coatings showed higher microhardness, lower wear mass loss and friction coefficient compared with those of the pure Ni coating and Ni-TiB2 composite coatings. The wear mass loss of Ni-TiB2-Dy2O3 composite coatings was 9 and 1.57 times lower than that of the pure Ni coating and Ni-TiB2 composite coatings, respectively. The friction coefficient of pure Ni coating, Ni-TiB2 and Ni-TiB2-Dy2O3 composite coatings were 0.723, 0.815 and 0.619, respectively. Ni-TiBE-Dy2O3 composite coatings displayed the least friction coefficient among the three coatings. Dy2O3 particles in composite coatings might serve as a solid lubricant between contact surfaces to decrease the friction coefficient and abate the wear of the composite coatings. The loading-bearing capacity and the wear-reducing effect of the Dy2O3 particles were closely related to the content of Dy2O3 particles in the composite coatings.

Nickel and nickel-phosphorous matrix composite electrocoatings

Nickel and nickel-phosphorous matrix composite coatings reinforced by TiO2,SiC and WC particles were produced under direct and pulse current conditions from an additive-free Watts' type bath.The influence of the variable electrolysis parameters(type of current,frequency of current pulses and current density) and the reinforcing particles properties(type,size and concentration in the bath) on the surface morphology and the structure of the deposits was examined.It is demonstrated that the embedding of ceramic particles modifies in various ways the nickel electrocrystallisation process.On the other hand,Ni-P amorphous matrix is not affected by the occlusion of the particles.Overall,the imposition of pulse current conditions leads to composite coatings with increased embedded percentage and more homogenous distribution of particles in the matrix than coatings produced under direct current regime.

Evolution of deformation-induced texture and surface microstructure of nickel coating under deep cup-drawing process

The deformation texture and surface microstructure of nickel coating induced by deep cup-drawing were studied by X-ray diffractometry and SEM. The steel sheet with nickel coating was firstly punched to designed degree of cup shapes. Then the texture of the coating was determined by XRD and the surface microstructure was observed by SEM. The results indicate that,the nickel coating material includes three kinds of textures,i.e. Ni(111),Ni(200) and Ni(220). After cup-drawing deformation,there doesn't appear new texture component for nickel coatings but the change of the intensity of the deformation textures. In the cup-deformation process,the two kinds of main textures Ni(111) and Ni(200) increase in the first and second cup-drawing procedures and then reduce quickly in the third and fourth drawing procedure. However,for the Ni(220) texture,it always increases in whole cup-drawing procedures. With the increase in the drawing,there are some cracks to be found,but not delamination. This shows that nickel coating and the substrate have a good combinable performance.

Computation of deformation-induced textures in electrodeposited nickel coating

The deformation-induced textures in electrodeposited nickel coating were numerically studied. The finite element method (FEM) for polycrystalline was developed based on Taylor model. Then the deformation-induced textures in electrodeposited nickel coating with initial random and lamellar texture were simulated under tensile load. It is found that the initial textures significantly influence the deformation-induced textures. For nickel coating with the initial random textures, when the tensile strain is about 40%, there are some lamellar textures. For nickel coating with the initial lamellar textures, the lamellar texture is more intensity with the increase of the tensile strain. With the increase of the tensile strain in the coating, there are more pronounced element distortion and a more inhomogeneous deformation. Due to the different crystal orientations, the grain-scale roughness is observed. With increasing tensile strain in the coating, the surface grain-scale roughness increases on the free surface. The surface roughness of the coating with initial random texture is lower than that with the initial lamellar texture.

ELECTRODEPOSITION OF AMORPHOUS Ni-P ALLOY COATINGS

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Cup-drawing formation of steel sheet with nickel coating by finite element method

The finite element method(FEM) simulation of deep-drawing of steel sheet with nickel coating based on the solid element and dynamic explicit method was reported. Penalty function method was used to treat the contact algorithm. The friction between the punch and coating sheet was based on a Coulomb formulation. The combination of coating and substrate was defined as tied with failure contact. The results of the simulation illustrate that the steel sheet and the nickel coating do not delaminate at the interface. The stress field of the nickel coating is more complicated than that of the steel substrate. Furthermore,it is found that the punch-nose radius is the most unsubstantial part for the intensity of the entire deep-drawing part and the thinnest part,it is a dangerous zone for the break. At this zone,the thickness thinning of the steel sheet and the nickel coating are up to 4.8% and 6.7%,respectively. Meanwhile,it is found that the curve of the variable blankholder force(VBHF) designed can improve the formability of sheet.

不同电流密度下电沉积金刚石增强镍基复合涂层的微观结构与耐磨性能

采用电沉积技术在1,2,5,10 A·dm^(-2)电流密度下制备金刚石增强镍基复合涂层,研究了复合涂层的微观结构和耐磨性能;通过COMSOL软件对阴极表面镍晶粒生长情况进行仿真,分析了不同电流密度下金刚石颗粒对复合涂层微观结构的优化作用。结果表明:在1,2 A·dm^(-2)电流密度下复合涂层的结构致密均匀,金刚石含量较多,随着电流密度的增大,金刚石含量减少,涂层表面出现金字塔结构;复合涂层呈现出明显的[200]丝织构,随着电流密度的减小,织构强度降低,晶粒尺寸减小。小电流密度下更多金刚石颗粒的沉积阻碍了其底部镍晶粒的生长,且金刚石颗粒周边较高的电流密度使得金刚石对镍晶粒的细化作用加强。在干摩擦的条件下,随着电流密度的增大,复合涂层的稳定摩擦因数和磨痕尺寸增大,磨粒磨损程度增大,耐磨性能降低;当电流密度为1 A·dm^(-2)时,复合涂层的稳定摩擦因数最小,磨痕深度和宽度最小,耐磨性能最好。

Effect of Some Plating Variables on Zinc Coated Low Carbon Steel Substrates

This work examined the effect of plating variables on zinc coated low carbon steel substrates. The electrodeposition of steel substrates was carried out in zinc electrolyte bath. Time, voltage, distance from the anode to the cathode and the immersion depth served as plating variables. The results showed that weight gained increases as the plating time increases for the constant depth of immersion while the weight gained per unit time by varying immersion depth is irregular. Also, the study demonstrated that sample plated for 20 minutes;20cm from the anode, 45cm depth of immersion at 0.8V exhibited the best plating properties with homogeneity of diffuse plating efficiency.

pH值对电镀镍镀层析氢性能的影响

在氨磺酸体系中,改变镀液pH值在紫铜表面制备镍镀层。通过扫描电镜(SEM)、线性极化曲线(LSV)、塔菲尔曲线(Tafel)、电化学阻抗谱(EIS)和计时电位法(CP)等方法对镍镀层的微观形貌、析氢性能和稳定性进行了测试。结果表明,当镀镍液的pH值为3.8时,镍镀层结晶细致且均匀,优化后的镍镀层暴露出更多的电催化析氢活性位点,在碱性电解液中表现出最佳的析氢性能,同时具有良好的析氢稳定性。

电沉积镍钨合金多层膜耐蚀性能研究

为满足微电子器件在极端环境中的服役要求,提升镍基合金薄膜镀层在工业应用中的耐蚀性,采用电沉积的方法得到单层及多层镍钨合金薄膜,研究了多层镀层对镍钨镀层耐蚀性能的影响。结果表明:在相同镀层厚度条件下,采用多层镍钨合金沉积方式能够提升镀层的耐蚀性能,为改善镀层耐蚀性能提供了一种方便而有效的途径。

Cr颗粒浓度对车轴上电沉积石墨增强Ni基涂层结构的影响

在电沉积Ni-C过程中添加不同浓度含量Cr颗粒得到Ni-Cr-C保护涂层,分析了Cr颗粒浓度对Ni-Cr-C保护涂层性能的优化效果,测定了涂层表面硬度。结果表明:形成了较平滑的Ni-C涂层,大部分区域呈现规则多边形形态。添加Cr颗粒后,表面区域形成了一些无规则外形的结节状组织,产生了大量孔隙。逐渐提高Cr颗粒量后,在涂层表面形成了尺寸更小的孔隙。当Cr颗粒的含量提高后,在涂层内形成了不同最高强度的Ni衍射峰,从原先的(110)晶面转变成(101)晶面。当Cr颗粒含量提高后,形成了更小Ni晶粒,加入80 g/L的Cr颗粒时Ni晶粒外径尺寸为29.2 nm。可通过加入Cr颗粒来制备硬度更高的涂层;且随Cr含量提高,沉积层的硬度也随之上升。更高含量的Cr颗粒(80 g/L)时,Ni-Cr-C层获得了更高的硬度551 HV。

ZrO_(2)用量对镍−钼−二氧化锆复合镀层性能的影响

以硫酸镍和钼酸钠为主盐,在镀液中添加ZrO_(2)纳米颗粒作为陶瓷相,通过直流电沉积方式制备了厚度为6.9~8.7μm的Ni–Mo–ZrO_(2)复合镀层。研究了ZrO_(2)用量对Ni–Mo–ZrO_(2)复合镀层微观结构、力学性能与耐腐蚀性能的影响。结果表明,随着镀液中ZrO_(2)质量浓度的增大,Ni–Mo–ZrO_(2)复合镀层中ZrO_(2)的质量分数增大,表面形貌、耐磨性和耐蚀性先改善后变差,纳米硬度先升高后降低。镀液中ZrO_(2)质量浓度为10 g/L时复合镀层的耐蚀性最佳,ZrO_(2)质量浓度为20 g/L所得Ni–Mo–ZrO_(2)复合镀层的微观结构和力学性能都最佳。

纳米镍涂层对铜合金耐腐蚀性能的影响

通过电镀在铜合金表面获得晶粒尺寸分别为10~20 nm和0.2~0.3μm的镍涂层,采用透射电子显微镜对涂层的微观结构进行表征,采用电化学方法和盐雾试验测试了涂层的耐蚀性。结果表明:纳米镍涂层的腐蚀电位较高,试样表面形成了致密的Ni(OH)_(2)钝化膜,能有效隔绝腐蚀介质,耐腐蚀性能最好;经过216 h盐雾试验后,纳米镍涂层表面仍可观察到镜面光泽,微米镍涂层表面出现了明显的腐蚀产物堆积,这进一步证明纳米镍涂层的耐蚀性更好。