Water-Lubricated Ni-Based Composite (Ni–Al2O3, Ni–SiC and Ni–ZrO2) Thin Film Coatings for Industrial Applications

Abstract

In this work, pure nickel and Ni-based nanocomposite coatings (Ni–Al2O3, Ni–SiC and Ni–ZrO2) were produced on steel substrate by using pulse electrodeposition technique. The industrial performance tests were conducted to evaluate the wear resistance, corrosion resistance, adhesion strength and wettability behaviour of newly developed coatings. Rolling contact ball-on-disc tribometer was used to assess anti-wear behaviour of these coatings under water-lubricated contacts. The results showed that the wear- and corrosion resistance properties of nickel alumina and Ni–SiC composite coatings significantly improved than that of pure Ni and Ni–ZrO2 coatings. The adhesion and wettability results of Ni–Al2O3 composite showed better performance when compared to the rest of the coatings. The effects of incorporating nanoparticles on the surface microstructure, interface adhesion and distribution of the particles were also investigated. The coatings were characterized by using scanning electron microscopy, X-ray diffraction analysis and 3D white light interferometry. The wear failure behaviour of these coatings was further examined by post-test surface observation under optical microscope.