The Characteristics of Electrodeposited Nickel composite coatings- A Review

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

The Characteristics of Electrodeposited Nickel composite coatings- A Review

Varadaraj S1, Shreeprakash B1, B.M. Praveen2, Bharath K. Devendra2,3

1 Department of Mechanical Engineering, Srinivas University, Institute of Engineering & Technology, Mukka, Mangaluru, Karnataka, 574146, India.

2 Department of Chemistry, Srinivas University, Institute of Engineering & Technology, Mukka, Mangaluru, Karnataka, 574146, India.

3Department of Chemistry, M. S. Ramaiah College of Arts, Science and Commerce, MSR Nagar, MSRIT Post, Bengaluru, Karnataka, 560054, India. ***

Abstract - Foralongtime,environmentalprotectionofmetalliccomponentshasbecomeapressingconcernfortheengineering andmanufacturingindustries.Coatingtechnologyhasgainedprominencetomeettheneedsofindustrialdemands.Thecoatingis usedtoprotectthemetalsandensuretheproduct'sperformanceforalongtime.Amongothercoatingprocessessuchasthermal spray, spark plasma sintering, and chemical vapour deposition, the electrodeposition process has proven to be the most costeffectiveandsimple.ThepaperdiscussesthepropertiesofvariousNickelcompositeelectrodepositedProtectivecoatings.

Keywords:ProtectiveCoatings,Electrodeposition,Nickelcomposites.

1.INTRODUCTION

Electrodepositionisoneofthemostsuccessfulmethodforcoatingmetalduetoitsuncomplicatedandconsistentprocesswhich has unique advantages in the microstructure and property modification of the depositions.The components, phases, and microstructures of the deposits can be regulated by modifying the electrodeposition parameters, such as the deposition potential,currentdensity,electrolytecomposition,PHvalue,temperature,etc[1].Duetoflawslikewear,corrosion,andfatigue, alotofmachinepartsfail.Thecharacteristicsliketribological,mechanical,andcorrosionresistanceareboostedbycoatingthe reinforcingmaterialonit[2].Therecommendedmethodisnickelplatingbecauseitisrenownedforitsconsistentplating thicknessontheplatedsurfaceandtheeasinesswithwhichintricatecomponentscanbecoated.Italsopossessesexceptional levelsof hardnessandcorrosion resistance[3].Theanti-wear qualitiesof the nickel coating have expanded theirrange of possibleusesfordies,tools,andworkingpartsforcarsandothervehicles.Withtheavailableone,thespectrumofalloysmight beexpandedforfunctionalpurposes.Bymodifyingthecompositecoatingonthematerials,itisfeasibletoavoidusingpricey heattreatmentproceduresonstandardalloys.[4].Theelectro-chemicalprocessisimportantinthefieldofnanotechnology.The co-depositionofcompositematerialparticlesdispersionandthepresenceoftheseparticlesinthecoatingareaccomplished usingelectrolytebathscontainingmicron/sub-micron-sizedparticles.Thetypeofcompositecoatingmaterialparticlesand theirinclusiondeterminethequalitiesofthecoatingmaterial.[5][6].

2. Electrodeposition

Electrodepositionprocesscanaccomplishthereductionofthedesiredmetal'scationsbeforetheyaredepositedonthesurfaceof aconductingsubstrate.Twoconductiveelectrodesareusedinthecoatingsetup,andtheyaresubmergedinanelectrolytebath. Theworking-cathodeorelectrodeisthoughttobeasingleterminalconnectedtothenegativeterminal.Onemoreisreferredto asacounter-electrodeoranodeandisattachedtothepositiveterminal.Thecationstraveltothecathode,aredischarged,and thendepositasametalliclayerwhenanexternalelectricfieldisintroduced.Electrodepositionistheidealtechniqueforachieving a smooth and ideal contact between the matrix metal and ceramic particles. [7][8]. Electrodeposition, often known as electroplating, isa technique for electrolytically depositing a coatingon a substratethat is immersedin an electrolyte. An aqueous medium at room temperature can be used for this. Aqueous solution electroplating refers to the method of electroplatingaqueoussolutionsatroomtemperature.usingafused-saltsolution,alsoknownaselectroplating,orinahightemperature fusion salt. One of the major drawbacks of electrodeposition is the inability to obtain consistency in coating thickness. Other limitations of the substrate include hydrogen ion assessment and essential surface preparation [9]. Electrodepositioniswidelyutilisedforaestheticcoatingsaswellascorrosionandwearresistance.Itisalsousedinspecialised applications including high temperature resistance, biomedical, and ceramic coating by increasing the electrode potential [10].Electrodepositioncanproducemetallicsystemswithallofthesedimensionalities,whilethreedimensionalsystemshavethe largestvarietyofapplications[11].Bothdirect(DC)andpulsecurrentcanbeusedintheelectrodepositionprocess(PC).The

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coatingcanbeappliedtothesubstrate'ssurfacetoimprovesolderability,lubricatingcharacteristics,electricalconductivity, corrosionresistance,wearandthermalresistance[12].Deeprecessesandirregularlyshapedgeometriescanbedepositedupon usingelectrodepositionwithlesssophisticatedplatingconditionsandequipment[13].

3. Composite Coating

Compositecoatingisanewtypeofcoatingdevelopedbymodernexperts.Normally,severaltypesofcompositematerialsare useddependingonthematrix.Examplesofthesematerialscompositesincludeceramicmatrixcompositesandmetalmatrix composites. Composites include things like carbon matrix composites and polymer matrix composites [14]. Metal matrix compositecoatingisoneofthemostwidelyutilisedintheindustryduetoitsefficiency[15].MMCcoatings,whichcombinethe ceramicphase'shighhardnessandstrengthwiththematrix'ssoundtoughness,arefrequentlyutilisedforsurfacerepairand strengtheningofengineeringmetalcomponents.Theinclusionofreinforcingparticlescanbedoneintwoways.Duetothelow wetting capabilities of the ceramic and metallic phases, particle-matrix bonding is fundamentally difficult with external additionorexsitu.Theceramicreinforcingphaseofthecoatingiscreatedbyanin-situchemicalreactionbetweenelementsof the precursor material at a very high temperature, followed by in situ nucleation and growth.These hard particles are consequentlymorethermodynamicallystableandfinerthanhardparticlesinjectedfromtheoutside.Therearemultiplesorts and designs of composite coatings. Composite coatings of different forms, shapes, sizes, and quality can be produced by choosingtherightceramicandmatrixcoatingmaterials,procedures,andtechnologies[16].Al,Fe,Mg,Ti,Ni,BeandCoare someofthecommonlyusedmaterialsformetalmatrixcomposites[17.18].Metalmatrixcomposites'(MMC)propertiesare generally determined by their composition and structure [19]. To maximize coating characteristics, a homogeneous distributionandlargenumberofparticlesparticipatinginthemetalmatrixarerequired[20,21].Enhancedcoatingperformance isoftencausedbymodificationstothegrowthmodeorgrainsizeofthemetalmatrix.[21,22].Thesize,diversity,andshapeof theimplantedparticles,aswellascurrentdensity,pH,electrolyteagitation,andbathcomposition,arealldependentfactors thataffectparticleincorporation[23].Duetotheenormouspotentialfordevelopingmaterialswithspecialisedfeatures,MMCs havefounduseinavarietyoffields[13].TheNi-basedMMCcoatingisoneofthemostchallengingandinterestingmetalmatrix coatings[15].Manycompositecoatingshavebeenextensivelyelectrodeposited,includingNi-SiC,Al203,Tio2,Zro2,Si3N4,Mo,Cr, and others [8].Nickel-based composite coatings have opened up new possibilities because of their exceptional wear and corrosionresistanceaswellastheirhighhardness[15].Ontribologicalparametersincludingcoefficientoffriction,hardness, roughness,andwearrate,variousalloyingelementsandhardparticlesincorporatedinthenickelmatrixhaveavarietyof effects.Thesefactorscancausethevalueofcharacteristicstoriseorfall[24]

Fig -1:ApplicationsofElectrodepositedNickelcoating[24]

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Numerous chemical, mechanical, and electrical processes require nickel and alloys including nickel phosphorous, nickel tungsten,nickelcobalt,andothers.Theimportanceofcompositecoatingswithsuperiorwearresistanceisrisingalongwiththe demandforlongerindustrialcomponentservicelives[25].TheapplicationsofnickelcompositecoatingsareshowninFig.1, whichrangefromthemaritimesectortothelockindustry.Theadditionoftheparticlesraisesthecoating'shardnessandwear resistancewhilealsoloweringitscoefficientoffriction.Amongotherengineeringcomponents,anickel-basedcoatingisapplied tocuttingtools,turbineblades,rollers,plungers,rollingmillrolls,extruders,pistonheads,androds[15].

3.1 Similar Electrodeposition work carried out

Mohanreddyetal.[26]studiedtheelectrodepositionprocedureusedtomakeaNi-Si3N4 coating.Morecorrosionresistance wasseeninNi–Si3N4 nanocompositescontaining3g/LSi3N4nanoparticlesinthebathsolution.TheperformanceofNi-Si3N4 nanocompositespreparedinthepresenceofSDSwassubparincomparisontoNi-Si3N4nanocompositespreparedwithout SDS.Withouttheuseofasurfactant,Ni-Si3N4nanocompositeshavehighercorrosionresistanceandparticleinclusion.Inthe investigation,about9%ofthenanoparticlesweredepositedinthecoating.

DRashmietal.[27]investigatedtheelectrofabricationofnanostructuredNi-Fealloycoatingsonmildsteelusingasulphate bath.Forthecoating,thecompositionoftheelectrolytic bathandcurrentdensitywereadjusted.EnergydispersiveX-ray spectroscopyhasbeenusedtoidentifythecompositionoftheNi-Fealloy.Thecoatingsareuniqueinkind.Testsforcorrosion usingpotentiodynamicpolarisationandelectrochemicalimpedanceSpectroscopictechniquesindicatethat4Adm-2isthe lowestcorrosionrateinasolutionof3.5percentNaCl.TheVickershardnesstestandatomicforcemicroscopywereusedto measurethecoatings'hardnessandroughness,respectively.Thesurfacemorphologyofthecoatingswasexaminedusing scanningelectronmicroscopy.X-raydiffractionwasusedtocalculateandanalysethetexturecoefficient,phasestructure,and crystallitegrainsizeofthecoating.

RobertaLeeetal.[28]investigatedtheelectrodepositionofniobiumoxidefromavarietyofaqueousandnon-aqueoussolvent systems using sol-gel processing techniques. The process depends on protons and hydroxide ions being produced electrochemicallybyadjustingtheelectrochemicalpHofthesolution.Innon-aqueoussolutionscontainingtertiaryniobium alkoxides,two-electronreductionresultsinhydroxideions.Inaqueousalkalinesystemscontainingniobate,waterundergoes electrochemical oxidation, which results in a pH drop. Niobium oxide and mixed niobate are created as the niobate sol destabilisesandanelectrodecoatingforms.

BapuGretal.[29]studiedthedispersion-strengthenednickelwasgeneratedutilisingtheelectro-codepositionmethodusinga nickelfluoborateelectrolytecontainingvanadiumpentoxide(V2O5)particlesinsolution.Theeffectsofparticlesize,particle concentrationinthe bath,current density, pH, and temperatureonthevolume percent(vol.percent)integrationofV2O5 particlesinthecompositewereinvestigated.Investigationandcomparisonofthecomposite'scorrosionbehaviourina5% sodiumchloride(NaCl)solutionwithmildsteelandnickeldepositswerealsoconducted.ThepercentageofV2O5particlesin thecompositeincreasedwithrisingV2O5contentinthebathandrisingcurrentdensity.Thebath'soperationat6.0ampdm-2, pH3.0,and50"CproducedthebestincorporationofV2O5(12.6vol.percent).Accordingtocorrosiontesting,thecomposite prevents steel from corroding when there is NaCl present. In a NaCl solution with a pH of 3.0, the composites' corrosion resistanceisweakertothatofnickeldeposits,butinaNaClsolutionwithapHof6.5,theyoffercomparabledefence.

3.2 Components of Electrolytic bath

Thepreparationoftheelectrolyticbathwiththerightproportionisverymuchessentialfortheelectrodepositionquality.The nickelelectrodepositionmainlyconsistsofNickelsulphate,NickelChlorideand Boricacidinitselectrolyticsolution.The relatedparticlesiezinc,graphene,ironetcaretobeaddedwithrequiredproportion fornickelcompositecoatingalongwith theelectrolyticsolution.Theelectrolyticcompositiondataofthevariouscompositecoatingsaregiveninthetable.

SDS(SodiumDo-DecylSulphate),ananionicsurfactant,hasbeenshowntoboostthecoating'shardnessandimprove itsadherencetothematrix[30].Thecorrosionresistancehasincreasedandtheparticledistributionhasbecomemoreuniform duetotheadditionofmoreSDS,asurfactant,totheelectrolyticsolutionforNi-Alumina[31].Thecompositionandoperational parametersofvariousNickelcompositecoatingsarelistedinTable1.

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Table1- Compositionandparametersofelectrolyticbath

Composite Coating NiSo4.6H2O (Nickel Sulpate) (gL-1)

NiCl2.6H20 (Nickel Chloride)(gL1)

H3 B03(gL1)

Particles (gL-1) pH Temperature (ₒC) Current Density (A dm-2)

Time (min) Reference

Nickel–graphene 85-100 12to15 25-35 0.2 3-4 45±5ₒC 5 60 [32]

NickelGraphene 330 35 40 0.1 3.5 51±1ₒC 5 55 [33]

NickelGraphene 300 50 40 0.5,0.25,0.1 4±2 45±5ₒC 5 50-60 [34]

NickelGraphene 26.26 56.81 18.54 0.1 3.8-4 40ₒC 5.66 50 [35]

NickelGraphene 110-115 18-25 35-45 0.2,0.4 3-4 50ₒC 5 30 [36]

NickelGraphene oxide

NickelReduced Graphene oxide

240 45 30 0.1(GO) 3.54.5 55-60 ₒC 6to10 65 [37]

250 35 35 4.37 3-4 55ₒC 3.5 12h [38]

NickelGraphene 300 35 40 0.05 4±1 50ₒC 0.15-4 1-3 hours [39]

NickelGraphene 95-110 15-20 30-40 0.2 3-4 50-55 ₒC 5 50 [40]

NickelVanadium pentoxide

280 5 40 5to50 1-5 30-70 ₒC 2to10 8h [29]

NickelSi3N4 27 57 19 3 3 40ₒC 5 60 [41]

AsperthevariousliteraturedatabeinglistedoutintheTable1itisunderstoodthathightemperatureistheprerequisitefor electrodepositing nickel composite coating. Temperature ranging from 50-60оC is required fornickel composite electrodeposition.ThePHistobemaintainedbetween3-4andanaveragecurrentdensityof5-6A/dm-2 istobemaintained duringtheprocess.Mostoftheresearchershavecarriedouttheelectrodepositionworkfor60mins.

4. Results and discussions

Thecommonlymeasuredresultparametersoftheelectrodepositedcoatingsaresurfacemorphology,Corrosionpotential, Roughness,MicrohardnessandContactanglemeasurements.ThevariousresultsofNickelcompositesarelistedinTable2.

Table 2-ResultsSummaryofNickelcomposites

Coating Composition XRD /EDAX Analysis

Ni-Si3N4

Peaksdetectedfor Ni,Si3N4 not detecteddueto lower concentration

Corrosion Potential Microhardness SEM Analysis AFM Analysis Ref

Improvedcorrosion resistanceobserved withcurrentof 0.00812A/cm2 .

value:

Increased hardnessvalue observedwith about400HV

Moreuniform grainstructure isobserved

Hill-valleylike structurewith homogenous distributionofgrains [26]

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Ni-Co-CeO2

AdditionofCeO2 influencedthe growthofthe crystallites

Corrosionresistace increasedwiththe additionofCeO2

Withthe additionofCeO2, thecomposite coating's microhardness enhanced..

Polyhedral crystalsto nodularcrystals havebeen observed NA [52]

Theresultsofthevariousnickelcompositeelectrodepositioncoatingshavebeenpresentedintable2.Itwasfoundfromthe literaturesthatmildsteelwasthemostcommonlyusedsubstrateanditiswidelyusedmaterialinindustries,andhenceitis pronetocorrosion.Themechanicalproperties,surfacecharacteristicsandcorrosionpotentialshavebeenlistedformostofthe varietiesofnickelcompositecoating.Researchershavediscoveredthebettersurfacepropertiesandcorrosionresistance whichcouldpavethepathforwidespreadusageintheindustrialandcommercialusage.

4.1 Corrosion Investigation Techniques:

Tafel extrapolation method and AC impedance method are the most commonly used corrosion resistance measurements methods.Tafelextrapolationmethodusespotentialexcitationintheformofdirectcurrenttogivelargerandappreciable currentstomeasurethecorrosionrate,Sincethecurrentandpotentialarenonlinear,semilogarithmicplotsisobtainedcalled asTafelPlots.Utilizingalternatingcurrentpotentialexcitation,theACimpedancemeasuringapproachofferscrucialdetailson thecapacitive behaviourof thedoublelayerthatcontributestothecoatings'corrosionresistance.Itoffers detailsonthe polarityandquantityofchargespresentattheelectrodeandelectrolyte,whichareeasilycomprehendedbyexaminingthe impedancecurves.

5. Research Gap

AllofthestudiesdescribedthatinclusionofparticleslikeGraphene,Niobium,Vanadium,TitaniumOxide,Zincandboronwith nickelbyelectrodepositionhasprovedtoprovideenhancedcorrosionresistanceandmechanicalcharacteristics.Themajority oftheresearchershavenotfocusedonthelowerelectrolyteconcentrationoftheparticles,furtherthemechanicalproperties likemicrohardness,scratchresistance,roughness,profileandcontactanglearebarelyunexplored.

6. Conclusion

Nickelisincreasinglyusedinmanynewfields,puttingitincompetitionwithothermaterialsduetoitsspecialcombinationof qualities and traits and its many industrial applications. This has led to the development of innovative nickel processing methods. The review paper provides a comprehensive overview of the overall elements of electrodeposition of nickel composite coating. Nickel Composite coating have been vastly researched with various combination of the particles. The inclusionofnanoparticlesinthecoatingexhibitimprovedpropertiesintermsofroughness,microhardness,andcorrosion resistancewithanuniformdistributionoftheparticles.Theelectrodepositionoftheseparticlesatlowerconcentrationswith nickelanditsimpactoncorrosionandmechanicalpropertiesmustbeexploredinthecurrentstudy.Theresearcherscanstart workingontheanalysiswiththehelpofthispaper.

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