Amorphous electroless-plated Ni-P coatings readily form nanocrystalline at relatively low temperatures. The current efforts to investigate the impact of proportion of nanocrystals on hydrogen permeation remain relatively limited, particularly when seeking to determine the impact of surface and internal nanocrystals on hydrogen permeation. The present work addresses this issue by conducting detailed analyses for amorphous electroless-plated Ni-P coatings and heat-treated coatings with a greater nanocrystalline concentration. The results show that the plated state samples exhibit excellent hydrogen permeation barrier properties.In addition, the heat-treated coatings exhibit a greater surface free energy and lower corrosion resistance due primarily to the higher density of phase boundaries arising from the increased crystallinity. The hydrogen diffusion coefficient of the heat-treated coating remains relatively stable (between 1.148×10−11 to 1.517×10−11 cm2/s) with increasing hydrogen charging current from 1 to 10 mA/cm², while the hydrogen diffusion coefficient of the as-plated amorphous coating increases from 3.406×10−12 to 7.996×10−12 cm2/s with increasing hydrogen charging current. The diffusion of hydrogen in the amorphous coating is primarily governed by low activation energy positions (i.e., 23.16 kJ/mol) associated with gaps between short-range-ordered atomic clusters in the material. A few high-energy positions (i.e., 45.58 kJ/mol) may be related to reversible hydrogen traps. The increasing crystalline content arising under heat treatment drastically reduces the prominence of low activation energy positions.
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