Electroless Ni–P coating was deposited on steel substrate and the effect of intermediate temperature oxidation on crystallization mechanism and corrosion properties of the coating was investigated. Ni–P coatings were annealed at three different temperatures, viz. 200°C, 400°C and 600°C for 2h in air. Formation of nickel oxide (NiO) was observed in the coating upon annealing beyond the crystallization temperature (330°C). Crystallization mechanism provided insight about the step by step formation of long range ordered Ni,Ni3P and NiO phases.Improvement in the corrosion resistance of Ni–P coating compared to bare steel was found to be ∼21% on annealing at 400°C in air which gradually increased to ∼31% on annealing the coating at 600°C in air. Increasedcorrosion resistance at 400°C annealed coating was attributed to the formation of crystalline Ni and Ni3P phases. Two simultaneously effects have been identified for the increased corrosion resistance of the coating annealed at 600°C in air. (a) Formation of NiO layer which acts as a passivation layer and protects the underlying P enriched layer and (b) absence of an interdiffusion layer from substrate to coating.
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