Simulation and properties of jet-electrodeposited Ni-W–SiC coatings

Abstract

Recently, researchers have extensively explored material surface modification techniques, including electrodeposition, chemical plating, and laser melting. In this work, Ni-W–SiC coatings were prefabricated by employing the jet electrodeposition (JED) technique. The impact of the nozzle outlet diameter on the flow field within the processing area was analyzed through COMSOL simulation to determine the optimal nozzle size. The surface morphology, roughness, wear, and corrosion resistance of the coatings were evaluated using SEM, TEM, a surface roughness tester, a friction and wear testing machine, and full immersion corrosion tests. The results showed that nozzle outlet jet rates were 4.78, 2.91, and 2.12 m/s for outlet diameters of Φ1, Φ2, and Φ3 mm, respectively. The highest deposition rate of 10.68 µm/min was achieved with a nozzle outlet diameter equal to Φ2 mm. This nozzle condition imparted optimal kinetic energy to the plating solution, enhancing shear forces at the substrate surface and reducing the diffusion layer thickness. As a result, it promoted uniform incorporation of SiC nanoparticles and refined the Ni-W grain structure. Numerous SiC nanoparticles with a mean diameter equal to 41.5 nm were incorporated into the coating deposited at Φ2 mm. Similarly, Ni, Si, W, and C elements were observed in the cross-section of the coating. The XRD peaks at 44.6°, 51.5°, and 77.1° for all three coatings corresponded to the Ni-W (111), (200), and (220) crystal planes. The wear rate of the coating deposited at Φ2 mm was only 0.16 mg/min, indicating excellent wear resistance. Furthermore, few corrosion products were observed on the surface of the Φ2-mm coating, with a corrosion weight loss of 1.5 mg and a corrosion rate (V_c) of 0.08 mg/day.