Nickel-based Coatings Research Articles

Influence of Al2O3 and h-BN on Wear and Corrosion Performance of IN625 Nickel-Based Coating

IN625 offers high-temperature oxidation resistance, wear resistance, and stable chemical properties. To improve the corrosion and wear resistance of the Q345B steel surface, two types of metal matrix composites (IN625 + 1% Al2O3 and IN625 + 1% h-BN) were applied to the substrate surface using the laser cladding process. This study analyzed the hardness, electrochemical corrosion, friction, and wear properties of both the laser-clad specimens and the substrates. The results show that (1) the hardness and wear resistance of the fusion-coated coating were significantly improved compared with the base material. Notably, the hardness increased by 19%, and the coefficient of friction decreased by 41% compared with the IN625 + 1% h-BN coating. Furthermore, the hardness and wear resistance of the IN625 + 1% h-BN coating were superior to those of the IN625 + 1% Al2O3 coating, attributed to the formation of eutectic compounds such as NiB and Ni2B in the dendritic region. (2) The corrosion resistance of the IN625 + 1% Al2O3 coating exceeds that of the IN625 + 1% h-BN coating and is also superior to that of the substrate. This improvement is primarily attributed to the addition of Al2O3, which enhances solid solution strengthening within the dendritic crystals of the fused-coating layer, reduces the percentage content of inclusions, and elevates the corrosion resistance of the coatings.

Electrochemical exfoliation of graphene nanosheets and development of a novel efficient Ni-CeO2-Gr ternary nanocomposite coatings for dual functional anti-corrosion and wear-resistance

Nickel-based coatings offer excellent corrosion, wear resistance, and mechanical strength, and can be further improved with additives, making them ideal for harsh environments like marine and chemical industries. In the present study, graphene (Gr) nanosheets were synthesized via electrochemical exfoliation and a novel Ni-CeO2-Gr nanocomposite coating was prepared by an electrochemical co-electrodeposition technique on a Cu substrate in a traditional Watts bath. The coatings (pure Ni, Ni-Gr, Ni-CeO2 and the ternary Ni-CeO2-Gr) were characterized using optical microscopy, scanning electron microscopy (SEM) coupled with energy-dispersive spectrometry (EDS), X-ray diffraction (XRD), Raman spectroscopy, Vickers microhardness and micro-scratch tests. The electrochemical properties of the coatings were evaluated by electrochemical impedance (EIS) and DC-polarization measurements in 0.5 M NaCl. SEM-EDS, Raman, and XRD analysis confirmed the successful synthesis of high-quality graphene and the incorporation of CeO2 nanoparticles and graphene nanosheets into the nickel coating matrix. It was found that the ternary Ni-CeO2-Gr coating exhibited a high microhardness (915.6 HV), improved cohesive strength and enhanced corrosion resistance (544 KΩ.cm−2) compared to pure Ni coatings (30 KΩ.cm−2) due to the synergistic effect of the graphene and CeO2 duplex layer within the Ni matrix, forming a robust anticorrosion barrier. These findings offer valuable insights into the designing highly efficient materials for corrosion protection.

Effect of Electromagnetic Field Assistance on the Wear and Corrosion Resistance of Nickel-Based Coating by Laser Cladding

Offshore wind turbine generators usually demand higher requirements for key component materials because of the adverse working environment. Therefore, in this study, electromagnetic-assisted laser cladding technology was introduced to prepare the nickel-based composite coating on the Q345R matrix of wind turbine generator key component material. By means of Scanning Electron Microscope (SEM), X-ray diffraction (XRD), Energy Dispersive Spectrometer (EDS), the Vickers hardness tester, friction and wear tester, and electrochemical workstation, the effects of different magnetic field intensities on the macroscopic morphology, microstructure, phase composition, microhardness, wear resistance, and corrosion resistance of the coating were analyzed. The experimental results show that the addition of a magnetic field can effectively reduce the surface defects, improve the surface morphology, and not change the phase composition of the coating. With the increase in magnetic field intensity, the microstructure is gradually refined, and the average microhardness increases gradually, reaching a maximum of 944HV0.5 at 8 T. The wear resistance gradually increases with the increase in magnetic field intensity, especially when the magnetic field intensity reaches 12 T, the wear rate of the coating is reduced by 81.13%, and the corrosion current density is reduced by 43.7% compared with the coating without a magnetic field. The addition of an electromagnetic field can enhance the wear resistance and corrosion resistance of the nickel-based laser cladding layer.

Microstructure and Wear Resistance of In Situ Synthesized Ti(C, N) Ceramic-Reinforced Nickel-Based Coatings by Laser Cladding.

In recent years, laser cladding technology has been widely used in surface modification of titanium alloys. To improve the wear resistance of titanium alloys, ceramic-reinforced nickel-based composite coatings were prepared on a TC4 alloy substrateusing coaxial powder feeding laser cladding technology. Ti (C, N) ceramic was synthesized in situ by laser cladding by adding different contents (10%, 20%, 30%, and 40%) of TiN, pure Ti powder, graphite, and In625 powder. Thisestudy showed that small TiN particles were decomposed and directly formed the Ti (C, N) phase, while large TiN particles were not completely decomposed. The in situ synthetic TiCxN1-x phase was formed around the large TiN particles. With the increase in the proportion of powder addition, the wear volume of the coating shows a decreasing trend, and the wear resistance of the surface coating is improving. The friction coefficient of the sample with 40% TiN, pure Ti powder, and graphite powder is 0.829 times that of the substrate. The wear volume is 0.145 times that of the substrate. The reason for this is that with the increase in TiN, Ti, and graphite in the powder, there are more ceramic phases in the cladding layer, and the hard phases such as TiC, Ti(C, N) and Ti2Ni play the role in the structure of the "backbone", inhibit the damage caused by micro-cutting, and impede the movement of the tearing point of incision, so that the coating has a higher abrasion resistance.

The Influence of Adding B4C and CeO2 on the Mechanical Properties of Laser Cladding Nickel-Based Coatings on the Surface of TC4 Titanium Alloy.

The development of titanium alloys is limited by issues such as low hardness, poor wear resistance, and sensitivity to adhesive wear. Using laser cladding technology to create high-hardness wear-resistant coatings on the surface of titanium alloys is an economical and efficient method that can enhance their surface hardness and wear resistance. This paper presents the preparation of two types of nickel-based composite coatings, Ni60-Ti-Cu-xB4C and Ni60-Ti-Cu-B4C-xCeO2, on the surface of TC4 titanium alloy using laser cladding. When the B4C addition was 8 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1078 HV, which was 3.37 times that of the TC4 substrate. The friction coefficient was reduced by 24.7% compared to the TC4 substrate, and the wear volume was only 2.7% of that of the substrate material. When the CeO2 content was 3 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1105 HV, which was 3.45 times that of the TC4 substrate. The friction coefficient was reduced by 33.7% compared to the substrate material, and the wear volume was only 1.8% of that of the substrate material.

Adding WC Nano-particles to Nickel-Based Coating Deposited by PTA Process: Microstructure and Nanoindentation Hardness Characteristics

Adding WC Nano-particles to Nickel-Based Coating Deposited by PTA Process: Microstructure and Nanoindentation Hardness Characteristics

Preparation and characterization of high-performance in-situ synthesized WC reinforced nickel-based coatings

The WC prepared by in-situ synthesis usually has the deficiency of coarse grains and low synthetic content due to its low nucleation drive. In this work, different contents of WCs were added as nucleation sites to enhance the synthesis reaction between carbon and tungsten by reducing the nucleation energy. The results showed that the composite coatings were dense, crack-free, and mainly composed of WC and Fe0.64Ni0.36 phases. Due to a significant increase in the nucleation rate, the content of WC was increased from 38.08% to 53.15% and the WC grains were also significantly refined. The composite coating showed the lowest wear rate of 1.07 × 10−6 mm3 N−1 m−1 when the pre-added WC content was 15 wt%, which was ascribed to the high content of synthetic WC with high microhardness around 2200 HV0.1 and the fine grain strengthening of the large number of about 1 μm WCs.

Wear Resistance Evaluation of Self-Fluxing Nickel-Based Coating Deposited on AISI 4340 Steel by Atmospheric Plasma Spray

Materials with enhanced wear resistance are constantly in high demand. Nickel-based self-fluxing materials deposited by atmospheric plasma spraying (APS) have feasible wear resistance performance. This study aimed to evaluate the results of a nickel-based self-fluxing alloy coating deposited on AISI 4340 steel substrate using APS. Additionally, the temperature at which the remelting process achieved optimal results was investigated. The AISI 4340 steel substrate samples were coated with a self-fluxing NiCrBSiCFe powder by APS. The post-coating remelting process was performed in a controlled atmosphere tube furnace at 900, 1000, and 1100 °C. Microstructural analysis was carried out by Scanning Electron Microscopy (SEM) before and after remelting. The estimated porosity of the as-sprayed sample was 3.28%, while the remelted coating sample at 1100 °C had only 0.22% porosity. Furthermore, a microhardness measurement was conducted, and the best condition yielded an average value of 750 HV0.5. Tribological tests were performed to evaluate the coefficient of friction and wear rates, revealing that at 1100 °C, the as-sprayed coating had a wear rate of 9.16 × 10−5 [mm3/(N*m] and the remelted coating had 4.106 × 10−5 [mm3/(N*m]. The wear-loss volume was determined to be 14.1 mm3 for the as-sprayed coating sample and 3.6 mm3 for the remelted coating at 1100 °C.

Particulate scale MPFEM modeling on heat transfer of ni-based tungsten carbide composite coating

In this article, the effect of WC (Tungsten carbide) content on the macroscopic as well as microscopic temperature evolution patterns of nickel-based coatings was analyzed from the particle scale using the multi-particle finite element (MPFEM) method. The results show that the coating temperature decreases gradually in the radial direction and increases and then decreases in the axial direction for different WC contents. When the heat transfer time is ≤ 1 ms, the lower the content of WC particles in the coating and when arranged in structure B (random loose-packed) helps to improve the high temperature resistance of the coating, and when the heat transfer time is > 1 ms, the higher the content of WC particles in the coating and when arranged in structure A (random close-packed), it helps to improve the high temperature resistance of the coating.

Catalytic Properties of Electroless Nickel-Based Coatings Modified by the Magnetic Field

In this work the nickel-based coatings were obtained by electroless catalytic deposition on light-hardened resins dedicated for 3D printing by SLA method. The effect of external magnetic field application on the properties of nickel-based coatings was determined. During metallization, the magnetic field was applied to the sample’s surface with different orientations. Due to the magnetic properties of metallic ions, the influence of the magnetic field on coatings properties is expected. The coatings were analyzed by Energy-dispersive X-ray spectroscopy (ED S) the X-Ray diffraction (XRD ) methods, and surface morphology was observed by scanning electron microscopy (SEM). The catalytic properties in a hydrogen evolution reaction (HER ) were measured by electrochemical method in 1 M NaOH solution. The best catalytic activity has been observed in the case of the ternary Ni-Fe-P alloy deposited under a parallel magnetic field. The primary outcome of the presented research is to produce elements based on 3D printing from resins, which can then be metallized and used for highly-active materials deposited on complex 3D models. Furthermore, these elements can be used as low-cost, highly-developed sensors and catalysts for various chemical processes.

Erosion behaviour of low-pressure cold-sprayed Ni coatings for concentrating solar power receivers

Nickel-based coatings provide outstanding wear and erosion resistance making them particularly suitable for several applications, from aerospace and naval to automotive, energy, and electrical. Cold spray (CS) is encountering a growing interest as a promising technology to deposit thick and dense coatings for components used in energy power generation systems, such as the concentrating solar power (CSP) plants. In this article, nickel coating was deposited onto steel substrates by using a low-pressure CS. The erosion behaviour of the coating was evaluated by a solid particle impact test at two different impact angles. The coating erosion rate was 10 × 10−4 at a 60° impact angle, showing a combination of ploughing and cutting mechanisms.

Estimation of indenter depth during frictional treatment of nickel-based coatings using optical profilometry

ABSTRACT The paper determines the effect of frictional treatment of nickel-based coatings of different initial hardness on the degree of their hardening and the depth of the indenter's impact on the surface layer. Frictional treatment was carried out with hemispherical sliding indenters made of finely dispersed cubic boron nitride under a load of 150 N for coating A (wt.%: Cr – 14.8, B – 2.1, Si – 2.9, C – 0.48, Fe – 2.6, Ni – base) and 500 N for coating B (wt.%: Cr – 18.2, B – 3.3, Si – 4.2, C – 0.92, Fe – 2.6, Ni – base). Using instrumental microindentation and optical profilometry, it was shown that the deformation of the softer and more ductile coating A proceeds more significantly: its hardening during frictional treatment reaches 56%, and the indenter impact depth is up to 3.8 μm, while the corresponding indicators for the harder coating B are 8% and 1.5 μm. The depth of the indenter impact must be considered if frictional treatment is used as a finishing operation for parts with nickel coatings.

Novel blue diode laser cladding for high-performance nickel-based coatings on copper substrates

The high reflectivity and excellent thermal conductivity exhibited by copper substrates pose considerable challenges for conventional laser cladding techniques aiming to achieve high-performance coatings on their surfaces. In this study, a novel blue diode laser cladding approach was proposed to prepare nickel-based coatings on copper substrates. Under the conditions of a preheating temperature of 200 °C and laser power of 1500 W, a Ni60A coating was successfully fabricated on the surface of pure copper, with metallurgical bonding achieved and no crack defects observed. The average microhardness of the coating ranges from 468 HV0.1 to 775 HV0.1, which is approximately 8.8–14.6 times greater than that of the copper substrate. Furthermore, the wear resistance of the coating is approximately 3.6–4.7 times higher than that of copper at 25 °C, and approximately 3.8–5.4 times higher at 300 °C. The performance of the coating exhibit gradient variations in the cladding direction. Consequently, the challenges posed by the high laser reflectivity and the need for a high preheating temperature of copper substrate have been effectively overcome through the utilization of a blue laser cladding, facilitating the industrial-scale preparation of large-area coatings on copper components.

Corrosion behavior of electrodeposited nickel-based coatings with W, Mo, and TiOx

The corrosion behavior of electrodeposited nickel-based coatings with W, Mo, and TiOx as potential catalytic material for hydrogen evolution reaction (HER) in highly aggressive media, 0.5 M H2SO4 and 6 M KOH, is presented. A wide range of electrochemical and spectroscopic methods have been used, such as linear sweep voltammetry, open-circuit potential (OCP), electrochemical impedance spectroscopy (EIS), X-ray diffraction (XRD), X-ray fluorescence spectroscopy (XRF), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS) to characterize the coatings before and after a residence time of 336 h in the model corrosion environment. The NiW alloy and the NiWTiOx composite coating demonstrate the best corrosion resistance in an acidic environment due to the stable tungstate phase formation (H0.33O3W and H2O4W) on the surface. In alkaline environments, all the systems studied show enviable resistance, but the alloys containing molybdenum stand out.

Effect of WC Content on the Wear and Corrosion Properties of Oscillating Laser-Cladding-Produced Nickel-Based Coating

Pneumatic conveying pipe is an important part of the coal industry. Its working environment is harsh, and it is mainly affected by serious wear and corrosion, which affects its operating life. Studying a method of strengthening the pipe wall of pneumatic conveying pipe is of great significance. In this paper, nickel-based alloy coatings with different WC (tungsten carbide) contents were prepared using an oscillating laser-cladding process, and the micro-characterization characteristics, wear resistance and corrosion resistance of the laser-cladded layer were discussed. The main conclusions are as follows: The microstructure of the laser-cladded layer gradually grows from the plane crystals and cellular crystals at the bottom to the relatively coarse columnar crystals in the middle, and finally to a large number of equiaxed crystals in the upper part. Moreover, with an increase in WC content, more fine equiaxed crystals are formed, mainly due to the decrease in temperature gradient with the increase in distance from the fusion line. Also, with an increase in WC content, the hardness and wear resistance of the nickel-based alloy are improved. When 20% WC is added, the laser-cladded layer shows the best corrosion resistance in 3.5 wt.% NaCl solution, and its polarization resistance is 16% lower than that when 10% WC is added. This study provides a technical reference for improving the operating life of pneumatic conveying pipelines.

Дослідження впливу температури газу процесу холодного газодинамічного напилювання на адгезійну міцність нікелевмісних покриттів

The subject of the research is the influence of low-pressure cold spraying process parameters on the adhesive strength of the coatings. The goal is to ensure the maximum values of the adhesive strength of nickel-based coatings deposited by cold spraying by controlling the gas temperature at the nozzle inlet. The task is to investigate the effect of the temperature mode of the DYMET-405 machine on the adhesive strength of the coatings obtained from the Ni+Zn+Al2O3 powder mixture at constant other spraying parameters. Research methods. The experimental study of the adhesive strength was conducted on the tear using adhesive method in accordance with DSTU 2639-94. The metal-matrix composite powder mixture Ni+Zn+Al2O3 was used as powder material. VT3-1 titanium alloy was chosen as substrate material. Coatings were deposited using DYMET-405 low-pressure cold spraying machine. Temperature regulation at the nozzle inlet was performed by turning on the required temperature mode on the equipment control panel. Other spraying parameters remained constant during coating deposition process. The results. It was established that with an increase in the temperature of the gas in the nozzle, an increase in the adhesive strength of coatings is observed, on average from 9.5 MPa to 28.7 MPa. This can be explained by the fact that an increase in gas temperature leads to an increase in the velocity of the gas flow and, accordingly, of the powder particles in this flow. Higher particle impact velocity has a positive effect on the process of their deforming, filling of pores, densifying of coating layers, and finally increasing the adhesive and cohesive strength. The scientific novelty of the obtained results is that the dependence of the gas temperature at the nozzle inlet during low-pressure cold spraying on the adhesive strength of Ni+Zn+Al2O3 powder mixture coatings deposited on VT3-1 titanium alloy substrates was obtained. Conclusions. The practical value of the obtained results is that the obtained dependences of adhesive strength on gas temperature can be used for the development of cold spraying recommendations for the deposition of restorative coatings on parts made of titanium alloys, in particular in aircraft engines to eliminate operational defects.

Aspects of Thermal Protection of Machine-Building and Power Equipment: Application of Oxidation-Resistant Combined Nickel-Based Coatings

Introduction. In the areas of power engineering where the thermal energy of superheated steam is used, an important aspect of providing the reliability and safety of equipment is the heat resistance of the materials employed. In the manufacture of induction superheaters, the optimal material for the steam pipe (coil) is copper. However, its ultimate resistance to oxidation does not exceed 400 °C, which significantly limits the efficiency of steam generators. Therefore, the objective of the work was to study the kinetics of oxidation of the combined galvanic coating of the Mo-Ni-Cr system applied to copper tubular samples and intended for thermal protection of steam generator coils.Materials and Methods. A combined electroplating of the Mo-Ni-Cr system with a total thickness of 12–35 μm was formed on the experimental copper tubular samples. A Mo sublayer with a thickness of about 1.5 μm on the surface of the copper tube was formed to prevent the diffusion of Cu into the Ni coating. A 1.5 μm thick chromium layer on the coating surface acted as an indicator of the oxidation process. A comparative analysis of the oxidation processes of the copper surface and the combined coating of the Mo-Ni-Cr system on a copper substrate was carried out using the methods of optical and electron microscopy, energy dispersive analysis, and precision determination of the growth parameters of oxide films.Results. The intervals of thermal stability of the copper substrate and nickel coating were experimentally determined. The obtained experimental dependences characterized the parabolic law of copper oxidation with the formation of a single-phase diffusion zone of CuO at temperatures above 350 °C, and nickel at temperatures above 750 °C, when the transition of NiO monoxide into oxide Ni2O3 began. The growth of oxide films according to quadratic laws provided a rapid increase in the thickness of the films, the accumulation of stresses in them, cracking, and chipping.Discussion and Conclusion. It is shown that the Mo-Ni-Cr electroplating is resistant to heating during long-term operation up to temperatures of 750–800 °C. The functional roles of Mo and Cr in the coating architecture were described. The work focused on the applied aspect of using the coating under study to increase the thermal stability of the steam pipelines of industrial induction superheaters with low and medium power.

Mechanical optimisation of Ni coatings produced by low-pressure cold spray

ABSTRACT Nickel-based coatings are widely used as thermal barriers in several sectors thanks to their remarkable corrosion and wear resistance and outstanding stability at high temperatures. Recently, Ni coatings, produced with thermal spraying and vacuum techniques, have been investigated for solar power energy applications. In the present manuscript, low-pressure cold spray (LPCS) was used to deposit pure Nickel onto a steel substrate. The influence of gas temperature, nozzle stand-off distance, and advancing speed on morphological and mechanical properties were studied. The optimal deposition conditions were derived by ANOVA analysis. The hardness and the adhesion strength were approximately 160 HV and 26 MPa, respectively. The highest thickness obtained under the optimised deposition with a single pass was around 900 µm.

Microstructure and properties of laser cladding in-situ ceramic particles reinforced Ni-based coatings

Abstract In order to explore the effect of in-situ ceramic particles on the microstructure and properties of nickel-based composite coatings, the nickel-based coatings reinforced by the in-situ ceramic were prepared on the surface of 40CrNiMo steel using laser cladding technology. On the basis of NiCrBSi (Ni45) powder, 0 wt%, 5 wt%, 10 wt%, 15 wt%, and 20 wt% of B4C and ferrovanadium (FeV50) were added, which the atomic ratio of V to C was 1:1. Microstructure and phase analysis were carried out by metallographic microscope (OM), X-ray diffractometer (XRD), and scanning electron microscope (SEM). The results show that the NiCrBSi coating without B4C and FeV50 are mainly composed of γ-Ni, Cr23C6, Cr7C3, and CrB phases. After adding B4C and FeV50, the matrix is mainly composed of γ-Ni(Fe) solid solution, and strengthening phases such as CrB2 and VB2 appear in the coating. With the increase of the B4C and FeV50, the amount of CrB2 and VB2 increased, and the hardness and wear resistance were improved. When the addition amount of B4C and FeV50 is 10 wt%, the in-situ reinforced particles were uniformly distributed and the wear resistance of the coating was the best and was about 15 times that of Ni45 coating.

Improvement of the High Temperature Wear Resistance of Laser Cladding Nickel-Based Coating: A Review

Nickel-based coatings obtained by laser melting are broadly applied for surface modification owing to their high bond strength and exceptional wear resistance. Nickel-based laser cladding coatings are also extensively employed in high temperature wear environments. In this paper, the research progress on improving the high temperature wear resistance of laser cladding nickel-based composite coatings was reviewed by introducing a hard ceramic phase, adding solid lubricants and rare earth elements. On this basis, the material system to enhance the high temperature wear resistance of coating was summarized from the perspectives of the type, addition amount, morphology and distribution law of the hard ceramic phase, etc. The synergistic effect of various lubricants on improving the high temperature wear resistance of coating was discussed, and the action mechanism of solid lubricants in the high temperature extreme environment was analyzed. Finally, this paper summarizes the main difficulties involved in increasing the high temperature wear resistance of nickel-based coatings and some problems worthy of attention in the future development.