Search Results (34)

Ni-Mo alloy coating has shown exciting potential as a candidate to replace chromium coating. In this paper, Ni-Mo alloy coatings were successfully electrodeposited from a citrate/ammonia bath, and the effect of the bath pH values over a wide range (4–10) on the characteristics and corrosion resistance of Ni-Mo alloy coating was studied in detail. Results show that all the deposited Ni-Mo alloy coatings consist of a crystalline solid-solution Ni(Mo) fcc structure. An increase in bath pH values could facilitate the deposition of Mo, thereby increasing the Mo content and decreasing the crystallite size of Ni-Mo alloy coatings. However, there are subtle gaps between the coarse grains on the surface of the Ni-Mo alloy coating deposited at pH 10. These subtle gaps tend to form between the coarse grains on the surface of the electrodeposited Ni-Mo alloy coating because of the relatively high Mo content, refined grains, and appropriate morphology. The Ni-Mo alloy coating deposited at pH 9 exhibits optimal corrosion resistance, attributed to its lowest corrosion current density i_corr (7.31 × 10⁻⁶ A cm⁻²), the strongest polarization resistance (11.13 kΩ·cm⁻²), and impedance value, which are mainly contributed to by the coating resistance and charge-transfer resistance. Full article

Aluminum–copper alloys have garnered significant attention in modern engineering applications due to their exceptional strength-to-weight ratio, corrosion resistance, and thermal conductivity properties. This study investigates the tribological performance optimization of Al10Cu alloys through chromium coating deposition, focusing on coefficient of friction and mass wear analysis in dry sliding conditions. Cr-coated Al10Cu alloys were fabricated through powder metallurgy and electrodeposition techniques, with comprehensive tribological characterization performed using scanning electron microscopy combined with energy-dispersive X-ray spectroscopy, X-ray diffraction analysis, microhardness measurements, and dry sliding wear testing. The chromium coating exhibited exceptional surface hardness of 720.9 HV, representing a remarkable 15-fold improvement over the uncoated Al10Cu matrix hardness. Tribological evaluation demonstrated outstanding wear resistance with the Cr-coated Al10Cu system achieving only 0.10 mg mass loss compared to 0.55 mg for the uncoated alloy, representing an exceptional 81.8% reduction in material removal. Despite a nominal increase in the coefficient of friction from 0.618 to 0.733, the chromium coating effectively transformed the wear mechanism from severe material removal to a controlled mild wear regime. The results establish the Cr-coated Al10Cu system as a highly effective solution for applications requiring extended operational lifespans under dry sliding conditions. Full article

Major vibrational spectroscopy studies have focused on the preparation of chromium coatings via chemical processes (conversion coatings), and few studies have focused on electrochemical processes (electrodeposition). Initially, the chemical precursors were hexavalent chromium salts, but these compounds are now replaced by less toxic trivalent ions. There is a profound understanding of the process when vibrational spectroscopy is used in combination with other techniques. This is the case for chromium(VI) conversion coatings, and the results of several techniques, such as synchrotron infrared microspectroscopy, have made it possible to understand the structure of the two-layer coating and the chemical composition of each layer. Vibrational spectroscopy confirmed the mechanism for coating formation, in which ferricyanide was a redox mediator. In addition, vibrational spectroscopy was effective in determining the mechanism of corrosion resistance of the coatings. Conversely, there are very few studies on the electrodeposition of trivalent chromium ions, and the mechanics of electrodeposition are unknown. To simplify the use of spectroscopy, spectra of potassium dichromate and chromium(III) sulfate are presented as references for coating studies, and a compilation of $\mathrm{C}\mathrm{r}\left(\mathrm{I}\mathrm{I}\mathrm{I}\right)-\mathrm{O}$ and $\mathrm{C}\mathrm{r}\left(\mathrm{V}\mathrm{I}\right)-\mathrm{O}$ vibrational modes is provided to facilitate band assignment. Our review highlights that spectroscopic techniques have been insufficiently applied in this field; however, the results of vibrational spectroscopy accelerate the transition to safer Cr(III) technology. Full article

Amorphous cobalt-phosphorous (CoP) coatings are a candidate to replace hard chromium and other traditional coatings. Here, electrodeposition of both amorphous and crystalline CoP coatings was performed at room temperature and in an air environment. The bath composition and deposition conditions were optimized to offer a low cost, low maintenance, and safe process. The effects of various deposition variables such as solution composition, pH, duration, and mixing parameters were studied, and the reproducibility of the process was demonstrated. Selected coatings were then thoroughly characterized by a variety of techniques. The best amorphous/nanocrystalline coating contained ca. 6.4 wt.% P after 1.2 h of deposition, and 7.2 wt.% P after 4 h of deposition. The best crystalline coating contained ca. 2.7 wt.% P after 1.2 h of deposition and between 2.3 and 5.5 wt.% P after 4 h of deposition. The amorphous coating had excellent mechanical properties: a high hardness (7.8 ± 0.7 GPa), high Young’s modulus (153 ± 9 GPa), and surprisingly low coefficient of dry friction (between 0.11 ± 0.02 and 0.17 ± 0.01). The coating could not be scraped from the substrate using a diamond scalpel blade. In a standard adhesion test, the sample failed neither cohesively within the coating nor adhesively between the coating and the substrate. In the as-deposited conditions, the structure was uniform, nanocrystalline, or had nanocrystals embedded in an amorphous matrix. The crystallization temperature of the amorphous alloy was 284 °C, and the phase transformation occurred only between 300 and 400 °C. The coatings developed and comprehensively characterized herein may be considered for aerospace, magnetic storage, fuel cells, water splitting, and other applications. Full article

Enhancing the durability and tribological performance of babbitt alloys is critical for high-stress applications in automotive, marine, and industrial machinery. The present study explores the electrodeposition of chromium coatings on SnSb11Cu6 alloys to improve their microstructural, mechanical, and tribological properties. The coatings were applied through an electrolytic process and systematically characterized using scanning electron microscopy and energy-dispersive X-ray spectroscopy to evaluate their morphology, composition, and wear performance. The chromium coating exhibited a uniform thickness of 20.2 µm and significantly improved the surface hardness to 715.2 HV, far surpassing the matrix and intermetallic phases of the uncoated alloy. Tribological testing under dry sliding conditions demonstrated a 44% reduction in the coefficient of friction (COF) and a 54% decrease in mass wear for the coated alloy, highlighting the protective role of the chromium layer against abrasive and adhesive wear. To further analyze the frictional behavior, a deep learning model based on a one-dimensional convolutional neural network was employed to predict COF trends over time, achieving excellent accuracy with R² values of 0.9971 for validation and 0.9968 for testing. Feature importance analysis identified coating hardness as the most critical factor influencing COF and wear resistance, followed by matrix hardness near the coating. These findings underscore the effectiveness of chromium coatings in mitigating wear damage and improving the operational lifespan of SnSb11Cu6 alloys in high-stress applications. This study not only advances the understanding of chromium coatings for babbitt materials but also demonstrates the potential of machine learning in optimizing tribological performance. Full article

The current electrolytes used for metal electrodeposition mostly use aqueous solutions that limit the range and quality of possible coatings. Also, some of these solutions may contain toxic and corrosive chemicals. Thus, the importance of ionic liquids (ILs) and deep eutectic solvents (DES) becomes clear, as they can be used as green non-aqueous electrolytes for the electrodeposition of a range of reactive metals that are impossible to deposit in aqueous solutions and for the improved electrodeposition of metals that are deposable in aqueous solutions. This paper presents some examples of electrodeposition in ILs and DESs that are considered specific processes. Aluminum, as an active metal that it is impossible to electrodeposit in aqueous solution, was electrodeposited from a chloroaluminate IL. Moreover, the electrodeposition of Al was carried out in open air using a novel approach. Chromium was electrodeposited from a DES containing the environmentally friendly form of Cr (III) instead of toxic Cr (VI). Magnesium alloys, as water-sensitive substrates, were electroplated in an air and water-stable DES. Also, this paper discloses, for the first time, the procedure of pretreatment of Mg alloys for successful electroplating. Full article

The application of deep eutectic solvents (DESs) as an innovative class of environmentally friendly liquid media represents a significant advancement in materials science, especially for the development and enhancement of structural materials. Among the promising applications, DESs are particularly attractive for the electrodeposition of corrosion-resistant coatings. It is established that corrosion-resistant and protective coatings, including those based on metals, alloys, and composite materials, can be synthesized using both traditional aqueous electrolytes and non-aqueous systems, such as organic solvents and ionic liquids. The integration of DESs in electroplating introduces a unique capacity for precise control over microstructure, chemical composition, and morphology, thereby improving the electrochemical corrosion resistance and protective performance of coatings. This review focuses on the electrodeposition of corrosion-resistant and protective coatings from DES-based electrolytes, emphasizing their environmental, technological, and economic benefits relative to traditional aqueous and organic solvent systems. Detailed descriptions are provided for the electrodeposition processes of coatings based on zinc, nickel, and chromium from DES-based baths. The corrosion–electrochemical behavior and protective characteristics of the resulting coatings are thoroughly analyzed, highlighting the potential and future directions for developing anti-corrosion and protective coatings using DES-assisted electroplating techniques. Full article

Nowadays, Thin Dense Chromium (TDC) coatings are being industrially used in rolling bearings applications due to their claimed advantages such as high hardness, low wear, and good corrosion resistance. However, despite their broad commercial use, very little has been published in the open scientific literature regarding their microstructure, nanomechanical, and tribological properties. In this paper, TDC coatings with a thickness of about 5 µm were deposited by a customized electrochemical process on ASTM 52100 bearing steel substrates. Surface microstructure and chemical composition analysis of the TDC coatings was carried out by scanning electron microscopy and atomic force microscopy. The results revealed a coating with a dense, nodular, and polycrystalline microstructure. Unlike standard electrodeposited “Hard Chromium” coatings, TDC coatings show no presence of micro/nano-cracks, likely contributing to their superior corrosion resistance. The nanomechanical behavior, studied by nanoindentation as a function of penetration depths, exhibits a pronounced size effect near the coating surface that can be linked to the nodular microstructure. A hard surface with hardness H_IT 14.9 ± 0.5 GPa and reduced elastic modulus E_r = 216.8 ± 3.9 GPa was observed. Tribological characterization under the presence of lubricants was performed by two single-contact tribometers using coated and uncoated steel balls against flat steel substrates. An in-house fretting wear rig was used to measure the lubricated friction coefficient in pure sliding conditions, whilst the friction performance in rolling/sliding lubricated conditions was evaluated using a WAM test rig. In pure sliding, TDC/TDC contacts show ~13% lower friction than for steel. Under rolling/sliding conditions with 5% sliding, the traction coefficient of TDC/TDC coating contact was at least 20% lower than that for steel/steel contact. The tribological results obtained in various contact conditions demonstrate the benefits of applying TDC coatings to reduce bearing friction. Full article

In this study, we have prepared Ni-W/Cr₃C₂ composite electrodeposits through the diffuse reinforcement mechanism of chromium carbide nanoparticles. These electrodeposits exhibit excellent corrosion resistance and are designed to effectively protect the structural materials of pipe columns under the harsh CO₂ corrosion environments faced by carbon sequestration and utilization technologies. A systematic investigation was conducted into the micro-morphology, profile undulation, phase composition, and surface chemical state of the electrodeposits. Furthermore, the corrosion-resistant behavior of Ni-W/Cr₃C₂ composite electrodeposits was investigated in simulated corrosive environments (i.e., brine solution containing 3.5 wt% NaCl and CO₂-saturated brine). We then evaluated their corrosion response under the aforementioned conditions using electrochemical methods. In addition, the EIS of electrodeposited coatings revealed that the dense oxide film layer formed on the surface of the deposits, which acted as a primary barrier against corrosion, playing a pivotal role in maintaining the overall corrosion resistance of the material. Full article

Electrodeposited chromium plating continues to be widely used in a number of specialized areas, such as weapons, transport, aerospace, etc. However, the formation of texture, hydrogen content and residual stress can degrade the serviceability and lead to material failure. The effect of post heat treatment processes on the relationship of texture, hydrogen content, residual stress and corrosion resistance of hexavalent [Cr(VI)] chromium coatings deposited on Cr–Ni–Mo–V steel substrates was investigated. Macrotexture was measured by XRD. Microtexture, dislocation density and grain size were studied by EBSD. With the increase of the heat treatment temperature, it was found that the fiber texture strength of the (222) plane tended to increase and subsequently decrease. Below 600 °C, the increase in the (222) plane texture carried a decrease in the hydrogen content, residual stress, microhardness and an increase in the corrosion resistance. In addition, crack density and texture strength were less affected by the heat treatment time. Notably, relatively fewer crack densities of 219/cm², a lower corrosion current density of 1.798 × 10⁻⁶ A/dm² and a higher microhardness of 865 HV were found under the preferred heat treatment temperature and time of 380 °C and 4 h, respectively. The hydrogen content and residual stress were 7.63 ppm and 61 MPa, with 86% and 75% reduction rates compared to the as-plated state, respectively. In conclusion, in our future judgement of the influence of heat treatment on coating properties, we can screen or determine to a certain extent whether the heat treatment process is reasonable or not by measuring only the macrotexture. Full article

This review provides a systematic analysis of the literature data on the electrodeposition of composite coatings using plating baths based on a new generation of room-temperature ionic liquids known as deep eutectic solvents (DESs). Such systems offer several advantages over traditionally used aqueous electrolytes and organic solvent-based electrolytes. The colloidal–chemical properties of suspension and colloidal electrolytes for composite deposition are thoroughly examined. New theories describing the kinetics of the co-deposition of composite layers are characterized. The kinetics and mechanisms of electrochemical deposition processes of composite coatings with metallic matrices are discussed. Case studies regarding the electrodeposition of composite coatings based on electrodeposited copper, silver, zinc, tin, nickel, cobalt, and chromium from DES-assisted electroplating baths are described and systematized. The main prospective directions for further research in the discussed scientific area are highlighted. Full article

The electrochemical co-deposition of Cr-Co oxide coatings at room temperature on 304 stainless steel (SS) was studied using an electrolyte composed of a mixture of ethylene glycol (EG), hydrated metal chloride salts (MCln∙YH₂O), and water as a secondary hydrogen donor (HBD). Metallic Cu and Ni undercoats were applied to improve the adhesion of a posterior Cr-Co metallic and oxide layer. The electroactive events that took place during both electrodeposition processes were studied using cyclic voltammetry (CV) and chronoamperometry. The microstructure and composition of the surface layers were studied using scanning electron microscopy (SEM/EDS), X-ray diffraction (XRD) and cross-sectional elemental mapping via transmission electron microscopy (TEM). The surface of steel with the Cr-Co:EG-H₂O coating showed greater resistance to pitting corrosion (123.93 mV) compared to untreated stainless steel (62.3 mV). This sample showed a large hystere-sis area, which is associated with high resistance to pitting corrosion by the occurrence of a re-passivation of the sample at a Erep value of 24.31 mV. After the cyclic potentiodynamic polariza-tion (CPP) test, the lowest specific mass loss (0.001 mg/cm²) was achieved for the AISI 304 SS sample coated using EG-water solvents (Cr-Co:EG-H₂O), while the untreated AISI 304 SS reached a higher specific mass loss (0.01 mg/cm²). The Electrochemical Impedance Spectroscopy (EIS) tests showed that the uniform corrosion resistance varied significantly from the untreated AISI 304 SS (35 kΩ) to the coated sample (57 kΩ), which is attributed to the protection provided by the chromium and cobalt oxides coating. The best corrosion resistance achieved was correlated with a superhydrophobic character (with a contact angle of 158.41°) of the Cr-Co coatings. This was in turn a consequence of a needle-like morphology characteristic of these oxides. Full article

A literature review was conducted to examine the current understanding of the kinetics and mechanism of electrochemical reactions occurring during the electrodeposition of chromium coatings from electrolytes based on trivalent chromium compounds. The research in this scientific field is crucial, as it addresses the pressing need for an alternative to chromium plating processes that rely on solutions containing highly toxic and harmful hexavalent chromium compounds. Numerous literature data on the kinetics and mechanism of the stepwise reduction process of Cr(III) complex ions were analyzed. The influence of various additives and surfactants on the reaction kinetics of the stepwise reduction of trivalent chromium ions was considered. Special attention was given to the kinetics of the stepwise discharge of trivalent chromium ions in ionic liquids and deep eutectic solvents. Full article

The corrosion resistance of FeCoNiCr high-entropy alloy deposits was investigated upon being prepared by current electrodeposition. The coatings were co-deposited in an electrolyte of an aqueous ferrous, cobalt, nickel, and chromium sulfates solution. Energy dispersive spectrometry analysis demonstrated that all four elements were co-deposited successfully. At the same time, the results from SEM indicate that the surface of the coating exhibits a granular morphology, with uniform density and no presence of cracks, with sizes ranging from 500 nm to 5 μm. Furthermore, X-ray diffraction patterns enunciated that the as-deposited coatings were amorphous. The polarization curves of the FeCoNiCr high-entropy alloy coating were measured by an electrochemical workstation in 3.5 wt.% NaCl, 1 mol·L⁻¹ H₂SO₄ and 1 mol·L⁻¹ NaOH solutions. The results revealed that the coating exhibited excellent corrosion resistance. The corrosion mechanism of the FeCoNiCr high-entropy alloy coating was analyzed in different environments. Moreover, the scratch testing method was employed to determine the alloy adhesion on the substrate, with higher values obtained for the FeCoNiCr alloy. Full article

Due to the toxicity associated with chromium electrodeposition, alternatives to that process are highly sought after. One of those potential alternatives is High Velocity Oxy-Fuel (HVOF). In this work, a HVOF installation is compared with chromium electrodeposition from environmental and economic points of view by using Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA) for the evaluation. Costs and environmental impacts per piece coated are then evaluated. On an economic side, the lower labor requirements of HVOF allow one to noticeably reduce the costs (20.9% reduction) per functional unit (F.U.). Furthermore, on an environmental side, HVOF has a lower impact for the toxicity compared to electrodeposition, even if the results are a bit more mixed in other impact categories. Full article