Development and characterization of nickel phosphorus based nanocomposite coatings for corrosion protection of steel

Abstract

Corrosion is the major challenge faced by many industries like marine, automobile, oil and gas industry, etc. Nickel Phosphorus (Ni-P) based coatings are extensively studied to mitigate corrosion due to their improved corrosion resistance. However, these coatings lack mechanical strength limiting their applications. In the present study, novel Ni-P-X (X=TiC (titanium carbide) and ZrC (zirconium carbide)) were developed through the electrodeposition process. Various amounts of titanium carbide TiC nanoparticles (0, 0.5, 1.0, 1.5, and 2.0 g/L) and ZrC nanoparticles (0, 0.75 and 1.5 g/L) were co electrodeposited in the Ni-P matrix under optimized conditions and then characterized by employing various techniques. It is noticed that the concentration of reinforcing ceramic particles has a significant on the structural, mechanical, tribological, and electrochemical properties of Ni-P nanocomposite coatings. The structural analysis of both types of prepared nanocomposite coatings indicates uniform, compact, and nodular structured coatings without any noticeable defects. Vickers microhardness and nanoindentation results of Ni-P-TiC nanocomposite coatings demonstrate the increase in the hardness with an increasing amount of TiC nanoparticles attaining its terminal value (5.98 GPa) at the concentration Corrosion is the major challenge faced by many industries like marine, automobile, oil and gas industry, etc. Nickel Phosphorus (Ni-P) based coatings are extensively studied to mitigate corrosion due to their improved corrosion resistance. However, these coatings lack mechanical strength limiting their applications. In the present study, novel Ni-P-X (X=TiC (titanium carbide) and ZrC (zirconium carbide)) were developed through the electrodeposition process. Various amounts of titanium carbide TiC nanoparticles (0, 0.5, 1.0, 1.5, and 2.0 g/L) and ZrC nanoparticles (0, 0.75 and 1.5 g/L) were co-electrodeposited in the Ni-P matrix under optimized conditions and then characterized by employing various techniques. It is noticed that the concentration of reinforcing ceramic particles has a significant on the structural, mechanical, tribological, and electrochemical properties of Ni-P nanocomposite coatings. The structural analysis of both types of prepared nanocomposite coatings indicates uniform, compact, and nodular structured coatings without any noticeable defects. Vickers microhardness and nanoindentation results of Ni-P-TiC nanocomposite coatings demonstrate the increase in the hardness with an increasing amount of TiC nanoparticles attaining its terminal value (5.98 GPa) at the concentration