Electrochemical Deposition of Ni, NiCo Alloy and NiCo–Ceramic Composite Coatings—A Critical Review
Abstract
:1. Introduction
- (i)
- Low initial investment coupled with high rate of production.
- (ii)
- It can be used with a wide variety of shapes and sizes of substrates
- (iii)
- Ease of producing economically viable quantities of nanocomposite materials, with grain sizes as small as 10 nm.
- (iv)
- Products of electrodeposition require no further processing and can be used immediately after the process.
- (v)
- It is an easy concept that can be replicated in industry and laboratories with minimal technological barriers.
- (vi)
- Electrodeposited Ni coatings have exhibited superior density and lower porosity.
2. Electrodeposition Methods
2.1. Direct Current Electrodeposition
2.2. Pulse Current Electrodeposition
2.3. Jet Electrodeposition
2.4. Pulse Reversal Current Electrodeposition
- (i)
- Hindering sundries adsorption thereby altering the reaction mechanism,
- (ii)
- An increase in exchange current density,
- (iii)
- Lowering cathodic polarization,
- (iv)
- Current efficiency and yield improvements, and
- (v)
- (Strengthening conversion and diffusion.
3. Electrodeposition Parameters for Ni–Co Alloys
3.1. Effect of Co Concentration in Electrolyte
3.2. Current Density
3.3. Particle Content
3.4. Electrolyte Agitation
3.5. Temperature
3.6. Electrolyte pH
3.7. Pulse Frequency
3.8. Duty Cycle
4. Mechanism of Ni–Co–Nanoparticle Electrodeposition
5. Baths Used in Electrodeposition Process for Ni–Co Coating
5.1. Chloride Baths
5.2. Sulfate Baths
5.3. Sulphamate Baths
6. Additives
6.1. Boric Acid
- (a)
- Boric acid suppresses oxygen evolution. Gadad and Harris [77] researched on oxygen incorporation in electrodeposited Mi, Fe and Ni–Fe alloy coatings. It was reported that an increase in applied current density resulted in an increase in the content of oxygen in Ni coatings and this posed a detrimental effect to the magnetic and electrical properties of the coatings. Addition of boric acid reduced the oxygen incorporation in all three electrodeposition systems, with less than 2 wt% oxygen observed in all cases. The buffering effect is not attributed directly to the boric acid but more to the complexing ability of boric acid with metal ions in the electrolyte.
- (b)
- Boric acid promotes deposition of Nickel by acting as a catalyst. The adsorptive interaction of boric acid has also been observed in Ni–Zn alloy coatings where boric acid increased the current efficiency of the system at lower Zn (II) concentrations and increased the Ni content of the coatings at higher Zn (II) concentrations [78]. Significant change in primary nucleation rate coupled with suppressed secondary nucleation on coatings was also reported. Cyclic voltammetric deposition results have shown that the hydrogen evolution rate (HER) increases relative to the increase in boric acid concentration.
- (c)
- Boric acid as a pH buffer. In electrodeposition, the practical buffer range is given at pKa ± 1, but this value is much higher in the case of boric acid (9.23 ± 1 at 25 °C). This is an anomaly considering the pH of the Ni electrolyte is 4.0. The anomaly can be attributed to formation of weak bound complexes between nickel ions and boric acid, such that the said complexes act as pH buffers [79,80]. The presence of these complexes however, has yet to be confirmed experimentally. This pH buffering phenomena has been found to be significantly influenced by the applied current density. Tsuru et al. [76] reported that at lower current densities (below 1.0 A dm−2), the pH buffering properties of boric acid were exhibited.
- (d)
- Suppression of hydrogen evolution by boric acid. During electrodeposition, electric current flowing through the system causes an increase in pH and as a result, hydrogen gas is produced at the cathode. Hydrogen evolution at the cathode is detrimental to the reduction of metal ions, and therefore boric acid is added into the plating bath solution to prevent electrode surface passivation as well as act as a surface agent which acts as a selective membrane to block passage of the reduction of Nickel, while permitting the reduction of iron in a retarded state. Improving the electrodeposition current density range thereby minimizes the effect [81]. Yin et al. [82] suggested that boric acid acted like a surfactant which was adsorbed onto the surface and hinders hydrogen evolution. The adsorbed boric acid interferes with the alloy nucleation process thereby reducing the hydrogen evolution rate in Ni-enriched phases [82]. It should be noted that the hydrogen evolution suppressing properties of boric acid have only been observed in presence of nickel ions and this suggests that there exists a mutual interaction between nickel and boric acid [76].
- (e)
- Reduction of passive film formation by boric acid during Ni electrodeposition. Boric acid was found to significantly deter surface passivation on Ni reduction in Fe–Ni setups [82]. Tsuru et al. [76] suggested that, by acting as a surface agent, boric acid hindered passivation of the electrode surface during reduction of nickel.
- (f)
- Accelerating growth rates of deposits. Boric acid improves the lateral as well as the outward growth rate during deposition of nickel [83].
6.2. Surfactants
6.3. Saccharin
- (i)
- Macroscopic stresses. These are caused by inhomogeneity in the deposited coatings. These comprise of either compressive or tensile stresses and they occur in galvanic cells.
- (ii)
- Microscopic stresses. These originate at grain boundaries and at locations where dislocations accumulate.
- (iii)
- Sub-microscopic stresses.
7. Properties of Electrodeposited Ni–Co Coatings
7.1. Microstructure
7.2. Mechanical Properties
7.3. Corrosion Behaviour
8. NiCo–Ceramic Composites
- (i)
- Reduction of exposed area open to corrosive media. Nanoparticles used in Ni–Co nanocomposite electrodeposition are usually ceramics. When these nanoparticles are uniformly distributed in the Ni–Co matrix, they minimize the metallic area that is exposed to corrosive attacks and, as a result, the corrosion potential is shifted to nobler values [128].
- (ii)
- SiC nanoparticles acting as physical barriers that hinder creation and propagation of corrosive pits.
- (iii)
- Nanosized SiC particles which offer greater corrosion resistance than micro-sized particles when used to deposit Ni–Co/SiC nanocomposites. Owing to their smaller sizes, such nanoparticles can access structural defects such as porosities and cracks thereby mitigating the corrosive effect at such locations.
- (iv)
- Formation of micro-galvanic cells. The metallic matrix acts as an anode while the nanoparticles act as cathodes when the Ni–Co nanocomposite coatings are exposed to corrosive media. Where the metallic matrix’s electrochemical potential is less positive than that of the nanoparticles, the corrosion mechanism of the micro–galvanic cells is transformed to uniform corrosion from pitting and localized corrosion [126].
8.1. Effect of Al2O3 Nanoparticles
8.2. Effect of SiC Nanoparticles
8.3. Effect of ZrO2 Nanoparticles
9. Applications
10. Future Scope and Recommendations
- (i)
- Corrosion resistance behavior in varying environments, such as steady and dynamic conditions.
- (ii)
- Tribological properties such as dry and wet abrasive behavior under controlled loads.
- (iii)
- Electroless deposition of Ni–Co coatings, which offers a more competitive and specialized option.
- (iv)
- Thermal oxidation resistance of Ni–Co alloy matrices.
- (v)
- More efficient electrolyte agitation techniques such as submerged jet impingement and flow cells, jet eductors, and ultrasound.
- (vi)
- Extensive research on hydrogen evolution mitigation in electrodeposited Ni-based coatings by using pulse electrodeposition and additives.
- (vii)
- Use of response surface methodology to optimize the Ni–Co electrodeposition process and increase accuracy of the desired properties and also predict tested properties.
Author Contributions
Funding
Conflicts of Interest
References
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Mbugua, N.S.; Kang, M.; Zhang, Y.; Ndiithi, N.J.; V. Bertrand, G.; Yao, L. Electrochemical Deposition of Ni, NiCo Alloy and NiCo–Ceramic Composite Coatings—A Critical Review. Materials 2020, 13, 3475. https://doi.org/10.3390/ma13163475
Mbugua NS, Kang M, Zhang Y, Ndiithi NJ, V. Bertrand G, Yao L. Electrochemical Deposition of Ni, NiCo Alloy and NiCo–Ceramic Composite Coatings—A Critical Review. Materials. 2020; 13(16):3475. https://doi.org/10.3390/ma13163475
Chicago/Turabian StyleMbugua, Nyambura Samuel, Min Kang, Yin Zhang, Ndumia Joseph Ndiithi, Gbenontin V. Bertrand, and Liang Yao. 2020. "Electrochemical Deposition of Ni, NiCo Alloy and NiCo–Ceramic Composite Coatings—A Critical Review" Materials 13, no. 16: 3475. https://doi.org/10.3390/ma13163475