Search Results (28)

The generation of high-purity hydrogen via chemical reaction from hydrogen-rich materials is one of the ways in the alternative energy industry. In this approach, the utilization of catalytic materials that possess the capacity to initiate the decomposition of the starting material and the subsequent release of hydrogen is of paramount importance. In this study, nickel/cobalt-plated copper catalysts (NiCo/Cu) are presented, comprising from 4 to 90 wt.% of cobalt as catalytic materials for hydrogen generation via sodium borohydride (NaBH₄) hydrolysis reaction. The NiCo/Cu catalysts were synthesized via electroless deposition from glycine-based baths, utilizing Ni²⁺ and Co²⁺ ions as metal sources and morpholine borane (MB) as the reducing compound. The catalytic performance in alkaline NaBH₄ hydrolysis was found to correlate with the cobalt loading in the coating. The maximum rate of hydrogen production, which was determined to be 14.22 L min⁻¹ gcat⁻¹, was achieved at 343 K for a catalyst composed of 90 wt.% Co. The reaction proceeded with the activation energy of 52.5 kJ mol⁻¹, while the catalyst exhibited high durability, preserving nearly 88% of its initial activity after five successive reaction cycles. The combination of nickel and cobalt, along with their synergistic effect and high efficiency in the borohydride hydrolysis reaction, makes them promising catalysts. Full article

This study conducts a systematic comparison of binary Ni-P, ternary Ni-W-P, and ternary Ni-Ce-P electroless coatings on 6061-T6 aluminum alloy, focusing on the effects of post-plating heat treatment at 300, 350, and 400 °C. The originality of this work lies in its direct comparison of W and Ce doping under identical conditions and its identification of a critical brittle transition that decouples hardness from wear resistance. All coatings achieved peak hardness at 350 °C, with Ni-W-P reaching approximately 1691 ± 45 HV_0.1 due to Ni₃P precipitation and solid-solution strengthening. However, a key finding is the severe embrittlement of the Ni-P coating at 300 °C, where its wear rate increased by over 50 times despite a hardness increase. Treatment at 400 °C degraded wear performance across all systems, likely due to precipitate coarsening and substrate over-aging. The best overall performance within the tested window was achieved with the Ni-Ce-P coating heat-treated at 350 °C for 1 h, which exhibited a fine nodular structure and reduced the wear rate by 98.9% compared to the bare substrate. These results highlight the importance of balancing hardness and toughness, identifying an optimized processing window for enhancing the tribological performance of lightweight aluminum components. Full article

Enhanced Giant Magneto-Impedance (GMI) effects of composite materials play a crucial role in producing devices with a good soft magnetic property. To improve this soft magnetic property, graphene is introduced to increase the conductivity of composite materials. However, the quality of graphene layers restricts the enhancement of GMI effects. There are few reports on the direct growth of graphene on Fe_73.5Si_13.5B₉Cu₁Nb₃ (FINEMET). In this paper, the composite ribbons of FINEMET coated with as-grown graphene are prepared by chemical vapor deposition (CVD), which is much better than previous results obtained by methods such as the transfer method or electroless plating in quality. The Ni layer, with good magnetic conductivity, is induced to the FINEMET as an auxiliary layer by the magnetron sputtering method for high-quality graphene-layer growth due to its high carbon dissolution rate. The results show that the growth temperature of the as-grown graphene layer on the FINEMET with the best GMI ratio could reach as high as 560 °C. Moreover, it was found that an Ni layer thickness of 300 nm has a crucial impact on GMI, with the maximum ratio reaching 76.8%, which is 1.9 times that of an initial bare FINEMET ribbon (39.7%). As a result, the direct growth of graphene layers on FINEMET ribbons by the CVD method is a promising way to light GMI-based devices. Full article

With the growing integration of electronic systems into modern infrastructure, the need for effective electromagnetic interference (EMI) shielding materials has intensified. This study explores the development of electroless Ni-plated fiber composites and systematically investigates the effects of post-heat treatment on their electrical, structural, and interfacial performance. Both carbon fibers (CFs) and glass fibers (GFs) were employed as reinforcing substrates, chosen for their distinct mechanical and thermal characteristics. Ni plating enhanced the electrical conductivity of both fibers, and heat treatment facilitated phase transformations from amorphous to crystalline Ni₃P and Ni₂P, leading to improved EMI shielding effectiveness (EMI-SE). NGF-based composites achieved up to a 169% increase in conductivity and a 116% enhancement in EMI-SE after treatment at 400 °C, while NCF-based composites treated at 800 °C attained superior conductivity and shielding performance. However, thermal degradation and reduced interfacial shear strength (IFSS) were observed, particularly in GF-based systems. The findings highlight the importance of material-specific thermal processing to balance functional performance and structural reliability. This study provides critical insights for designing fiber-reinforced composites with optimized EMI shielding properties for application-driven use in next-generation construction materials and intelligent infrastructure. Full article

Electroless nickel plating is a chemical deposition process in which nickel ions within a plating solution are reduced by a chemical reducing agent and subsequently deposited onto the surface of a solid substrate. Chemical nickel-plating wastewater contains substantial amounts of phosphorus as well as abundant nickel resources. In this study, electrodialysis coupled with advanced oxidation techniques was utilized for the efficient recovery of nickel and phosphorus from spent nickel-plating solutions. The end-of-life tank solution from chemical nickel plating was treated via electrodialysis to remove harmful phosphite and sulfate ions, enabling the purified solution to be reused in plating production by supplementing it with appropriate amounts of sodium hypophosphite and nickel sulfate. Subsequently, the concentrate generated from electrodialysis was treated using peroxydisulfate (PDS)-based advanced oxidation technology to break nickel complexation and simultaneously promote the oxidation of hypophosphite and phosphite ions. Finally, Ca(OH)₂ was employed as a precipitating agent to effectively recover phosphorus from the treated concentrate. From an economic perspective, optimal process conditions were determined as follows: a current density of 20 mA/cm², concentrate-to-dilute water volume ratio of 1:1, current speed of 1.0 m³/h, and a sodium sulfate concentration in concentrate of 20 g/L. Under these conditions, the migration rates of H₂PO₂⁻ and HPO₃²⁻ ions reached 67.3% and 62.53%, respectively, whereas Ni²⁺ exhibited significantly lower mobility at only 6.77%. The purified wastewater recovered approximately 60% of its initial plating activity. Regarding the concentrate—which is a by-product of electrodialysis—the hypophosphite ions were nearly completely oxidized using a PDS dosage of 0.3 mol/L. Furthermore, when the Ca/P molar ratio was adjusted to 2.0, total phosphorus (TP) and nickel (Ni) removal efficiencies exceeded 98% and 93%, respectively. Full article

The electrolysis of water is one of low-cost green hydrogen production technologies. The main challenge regarding this technology is designing and developing low-cost and high-activity catalysts. Herein, we present a strategy to fabricate flexible electrocatalysts based on nickel–iron (NiFe) alloy coatings. NiFe coatings were plated on the flexible copper-coated polyimide surface (Cu/PI) using the low-cost and straightforward electroless metal-plating method, with morpholine borane as a reducing agent. It was found that Ni₉₀Fe₁₀, Ni₈₀Fe₂₀, Ni₆₀Fe₄₀, and Ni₃₀Fe₇₀ coatings were deposited on the Cu/PI surface; then, the concentration of Fe²⁺ in the plating solution was 0.5, 1, 5, and 10 mM, respectively. The morphology, structure, and composition of Ni_xFe_y/Cu/PI catalysts have been examined using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), and inductively coupled plasma–optical emission spectroscopy (ICP-OES), whereas their activity has been investigated for hydrogen evolution (HER) and oxygen evolution (OER) reactions in 1 M KOH using linear sweep voltammetry (LSVs). It was found that the Ni₈₀Fe₂₀/Cu/PI catalyst exhibited the lowest overpotential value of −202.7 mV for the HER, obtaining a current density of 10 mA cm⁻² compared to Ni₉₀Fe₁₀/Cu/PI (−211.9 mV), Ni₆₀Fe₄₀/Cu/PI (−276.3 mV), Ni₃₀Fe₇₀/Cu/PI (−278.4 mV), and Ni (−303.4 mV). On the other hand, the lowest OER overpotential (344.7 mV) was observed for the Ni₆₀Fe₄₀/Cu/PI catalyst, obtaining a current density of 10 mA cm⁻² compared to the Ni₃₅Fe₆₅ (369.9 mV), Ni₈₀Fe₂₀ (450.2 mV), and Ni₉₀Fe₁₀ (454.2 mV) coatings, and Ni (532.1 mV). The developed Ni₆₀Fe₄₀/Cu/PI catalyst exhibit a cell potential of 1.85 V at 10 mA cm⁻². The obtained catalysts seem to be suitable flexible catalysts for HER and OER in alkaline media. Full article

Taking advantage of its high-temperature resistance and elongation properties, conductive-coated polyetheretherketone (PEEK) filament yarn can be used as a textile-based electroconductive functional element, in particular as a strain sensor. This study describes the development of electrical conductivity on an inert PEEK filament surface by the deposition of metallic nickel (Ni) layers via an electroless galvanic plating process. To enhance the adhesion properties of the nickel layer, both PEEK multifilament and monofilament yarn surfaces were metalized by plasma torch pretreatment, followed by nickel plating. Electrical characterizations indicate the potential of nickel-coated PEEK for structural monitoring in textile-reinforced composites. In addition, surface energy measurements before and after plasma torch pretreatment, surface morphology, nickel layer thickness, chemical structure changes, and mechanical properties were analyzed and compared with untreated PEEK. The thickness of the Ni layer was measured and showed an average thickness of 1.25 µm for the multifilament yarn and 3.36 µm for the monofilament yarn. FTIR analysis confirmed the presence of new functional groups on the PEEK surface after plasma torch pretreatment, indicating a successful modification of the surface chemistry. Mechanical testing showed an increase in tensile strength after plasma torch pretreatment but a decrease after nickel plating. In conclusion, this study successfully developed conductive PEEK yarns through plasma torch pretreatment and nickel plating. Full article

The development of Li-ion battery cases requires superior electrical conductivity, strength, and corrosion resistance for both cathode and anode to enhance safety and performance. Among the various battery case materials, super duplex stainless steel (SDSS), which is composed of austenite and ferrite as two-phase stainless steel, exhibits outstanding strength and corrosion resistance. However, stainless steel, which is an iron-based material, tends to have lower electrical conductivity. Nevertheless, nickel-plating SDSS can achieve excellent electrical conductivity, making it suitable for Li-ion battery cases. Therefore, this study analysed the plating behaviour of SDSS plates after nickel plating to leverage their exceptional strength and corrosion resistance. Electroless Ni plating was performed to analyse the plating behaviour, and the plating behaviour was studied with reference to different plating durations. Heat treatment was conducted at 1000 °C for one hour, followed by cooling at 50 °C/s. Post-heat treatment, the analysis of phases was executed using FE-SEM, EDS, and EPMA. Electroless Ni plating was performed at 60–300 s. The plating duration after the heat treatment was up to 300 s, and the behaviour of the materials was observed using FE-SEM. The phase analysis concerning different plating durations was conducted using XRD. Post-heat treatment, the precipitated secondary phases in SAF2507 were identified as Sigma, Chi, and CrN, approximating a 13% distribution. During the electroless Ni plating, the secondary phase exhibited a plating rate equivalent to that of ferrite, entirely plating at around 180 s. Further increments in plating time displayed growth of the plating layer from the austenite direction towards the ferrite, accompanied by a reduced influence from the substrate. Despite the differences in composition, both the secondary phase and austenite demonstrated comparable plating rates, showing that electroless Ni plating on SDSS was primarily influenced by the substrate, a finding which was primarily confirmed through phase analysis. Full article

Degradation of industrial machinery through wear can be mitigated with the deposition of protective coatings to reduce maintenance costs and prolong their service lifespans. Electroless nickel-based composite coatings is one possible method used to provide this protection. The addition of Tribaloy (CoMoCrSi alloy) particles has been found to produce composite coatings with high toughness. In this work, electroless Ni-P-Tribaloy composite coatings were plated on AISI 1018 steel substrates and subjected to low-stress abrasion tests following ASTM G65 standards to investigate the abrasion of the coating. The test was performed at 10 revolution increments, with a 45 N applied load, until coating failure was observed and the measured abrasion was reported as volume loss. The two Ni-P-Tribaloy coating samples lasted for 90 and 100 revolutions, exhibiting a wear rate of 0.170 mm³ per revolution, compared to 0.135 mm³ per revolution for the Ni-P coatings. The abrasive wear mechanism in the Ni-P-Tribaloy coating was found to be plowing of the matrix around the Tribaloy particles, followed by the removal of the particles once they are protruding, which subsequently contributes to the three-body wear of the coating. The particle removal was accelerated at the coating particle-matrix interface. It is concluded that the size of the Tribaloy is a major factor, and we recommend that further studies be carried out using finer particles to improve the wear resistance of the Ni-P-Tribaloy coating. Full article

Electroless Ni-B (ENB) coatings have industrial importance due to their excellent mechanical properties. The inclusion of W (ENB-W) to the coatings further enhances their mechanical properties and thermal stability. Nevertheless, the ENB or ENB-W coatings are deposited from a heavy metal-stabilized bath, and the very commonly used stabilizer is lead nitrate. The present work is an attempt to obtain an ENB-W coating with enhanced mechanical properties and elimination of the stabilizer from the bath. To achieve this, the coating bath temperature, the heat treatment temperature and the heat treatment duration were varied systematically following a strategy adopted from Taguchi’s experimental design. The mechanical properties targeted include surface microhardness and scratch hardness. Multi-objective optimization was performed using gray relational methodology. The predicted bath temperature was 85 °C, while the predicted heat treatment temperature was 450 °C and there was 3 h of heat treatment time. The optimized lead-free ENB-W coatings had a microhardness of 1096.2 HV₁₀₀ and scratch hardness of 13.86 GPa. In fact, single-objective optimization for surface microhardness and scratch hardness by Taguchi’s methodology also predicted the same optimal parametric condition for both scratch hardness and surface microhardness. This was comparable to that of a lead-stabilized ENB-W coating and higher than the as-plated stabilizer free ENB-W coatings. The coating failure of the optimized ENB-W alloy was tested using a progressive scratch test, which showed that there was no chevron or transverse cracks within the load range considered. Analysis of corrosion resistance revealed that the corrosion potential of the optimized coatings was −407 mV, and this was comparable to that of a lead-based ENB-W coating. Full article

Polyetheretherketone (PEEK) and its fiber-reinforced materials are thermoplastic polymer materials with broad application prospects. Depositing Ni-P alloy on them can improve their poor conductivity and electromagnetic shielding performance, and further expand their application field. The application effect of the plated parts is significantly impacted by the bonding strength between PEEK and coating. The bonding strength between non-metallic substrate and coating is largely influenced by the surface characteristics of the substrate. Therefore, it is significant to study how the surface roughness of PEEK materials and the modified fibers in materials affect the adhesion of the coating. In this study, Ni-P alloy was electroless deposited on PEEK, 30% carbon-fiber-reinforced PEEK (CF30/PEEK), and 30% glass-fiber-reinforced PEEK (GF30/PEEK) with varying surface roughness. The influence of surface roughness and modified fibers on the coating adhesion was studied. Additionally, the effect of the concentrations of nickel sulfate, sodium hypophosphite, pH, and temperature on the deposition rate of the coating was investigated for the three materials. Based on the highest deposition rate, the process parameters were then optimized. The results demonstrated that as surface roughness increased, adhesion between substrate and coating first increased and then decreased. The surface roughness R_a of 0.4 μm produced the highest coating adhesion. Additionally, fiber-reinforced PEEK adhered to coatings more effectively than PEEK did. The mechanism of the difference in bonding strength between different PEEK-modified materials and coatings was revealed. The optimal process parameters were: nickel sulfate: 25 g/L, sodium hypophosphite: 30 g/L, pH: 5.0, and temperature: 70 °C. Full article

Particulate fouling is a common fouling in heat exchange equipment, it causes tube corrosion and increases flow resistance. Particulate fouling increases the hidden danger of equipment and requires high treatment costs. In this paper, a novel Ni−P−TiO₂ composite coating is prepared on 316 stainless steel using electroless plating and the fouling inhibition characteristics of the novel composite coating are studied using a dynamic monitoring experimental system. The experimental results show that the fouling thermal resistance of the Ni−P−TiO₂ composite coating is obviously lower than that of 316 stainless steel under the same working conditions. With the increase in cooling water velocity and inlet temperature, the surface fouling thermal resistance decreases, while, with the increase in particle concentration, the fouling thermal resistance increases. Based on DLVO theory, it is found that the surface energy of Ni−P−TiO₂ composite coating is close to the best surface energy for inhibiting particulate fouling deposition, which can significantly inhibit particulate fouling deposition. Compared with the stainless-steel surface of a conventional plate heat exchanger, the Ni−P−TiO₂ composite coating not only inhibits the accumulation of particulate fouling, but also reduces the adhesion strength of particulate fouling; additionally, the fouling is easier to strip off the heat exchange surface, which realizes the lasting and efficient fouling inhibition on the heat exchange surface. The research results can provide a data reference for the fouling inhibition design and daily efficient operation of heat exchangers. Full article

The work aimed to produce Ni-P-MoS₂-Al₂O₃ on Al-7075 alloys with multiple attributes through an electroless (EL) plating route. The effects of additives (MoS₂ and Al₂O₃) in the EL bath on the surface morphology, topography, hardness, composition (phase and elemental), roughness, wettability, and coating thickness were evaluated. Results indicate a substantial enhancement in microhardness of the EL-coated surfaces by 70% (maximum hardness = ~316 HV) using powders, and 30% (244 HV) without powders. The maximum coating thickness and water contact angle obtained with powders were 6.16 μm and 100.46°, respectively. The coefficient of friction for the samples prepared using powders was 0.12, and for the base material it was 0.18. The compositional analysis through EDS and XRD suggested the incorporation of a hard and lubricious layer on the EL-coated surface owing to the presence of different phases of Al, Mo, P, Zn, O, and S. Therefore, the resulting coating surfaces impart hardness, self-lubrication, hydrophobicity, and wear resistance simultaneously. Full article

The use of rubber in dynamic contacts often results in severe degradation and wear of the rubber surface, which is why dynamic rubber seal contacts are usually oil lubricated to ensure their functionality. However, the increasing demand for more convenient and environmentally friendly sealing solutions has prompted the development of dry low-friction rubber coatings. In this work, and for the first time, Ni-P and polytetrafluoroethylene (PTFE) particles were co-deposited by electroless plating on Nitrile Butadiene Rubber (NBR), as a low-cost solution to improve the NBR tribological behavior. A cationic surfactant, cetyltrimethylammonium bromide (CTAB), was added to the plating bath to ensure a homogeneous and efficient incorporation of PTFE into the Ni-P. The optimized PTFE incorporation reached 6.8%, and the composite coating adhesion to NBR was 20% higher than that of nickel-phosphorous (Ni-P) films. The tribological properties of the coatings evaluated by pin-on-disk tests showed a marginal decrease in the coefficient of friction (CoF) (10%, 1 N load), compared to that of Ni-P. However, the tested PTFE-based coatings displayed significantly smoother surfaces with less debris and cracks, clearly demonstrating the benefits of the PTFE in terms of wear resistance for loads up to 5 N. Full article

To address the issue of poor corrosion resistance of the Mg–Li alloy, electroless Ni–P plating was used to create a protective coating. However, there were significant differences between the upper and lower surface coatings, which were summarized as follows: (1) compared with the lower surface, the longitudinal differences between different areas of the upper surface coating were larger; and (2) the denseness of the upper surface coating was insufficient in areas where the insoluble phase was concentrated, resulting in significantly lower corrosion resistance of the upper surface coating than the lower surface. Resolving these differences could compensate for the defects of the upper surface coating so as to improve the overall corrosion resistance of the material. Therefore, in this paper, the deposition process of Ni–P was observed and speculated, and the reasons for these differences were analyzed in combination with experimental phenomena. Based on these, two optimization measures were proposed. The SEM observation results showed that the differences between the upper and lower surface coatings were significantly reduced after optimization. The results of potentiodynamic polarization tests and EIS tests showed that the optimized upper surface coating had good corrosion resistance similar to the lower surface coating. Full article