Abstract Composite Nickel (Ni) coatings, which contain submicron graphite particles (400 nm in size), were deposited on AISI 1045 steel using a direct current electrodeposition technique from a Watts bath. The effects of different graphite particle concentrations (0, 0.2, 0.5 and 1 g l−1) on the surface and tribological properties of the composite Ni coatings were investigated. The introduction of graphite particles into a Ni electrodeposit was found to result in grain refinement, and the broccoli-like cluster structure was formed on the coating surface. Hence, the hydrophobicity of the coating was greatly improved. When the concentration of graphite particles is 1 g l−1, the hardness of the composite coating reaches 1346 ± 12.83 HV and the smallest width values of the wear scars as compared to the pristine Ni coating, which had a hardness of 268 ± 3.40 HV. These results reveal that the fine-grain strengthening effect and formation of a graphite-rich protective layer on the contact surfaces effectively enhance the tribological performance of the coating.
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