Shear-flow electrodeposition of graphene-nickel coatings with controlled parallel alignment for superior wear and corrosion resistance

IF 6.1 2区材料科学 Q1 MATERIALS SCIENCE, COATINGS & FILMS

Surface & Coatings Technology Pub Date : 2025-10-02 DOI:10.1016/j.surfcoat.2025.132752

Jianfeng Chen , Hongmin Xiao , Xiaobing Li , Wenhu Xu , Meirong Yi , Min Zhong

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Abstract

Graphene is an ideal reinforcement for wear- and corrosion-resistant coatings due to its high modulus and chemical inertness. Ni-graphene composite coatings are widely used to protect metal equipment in metallurgical, chemical, and petroleum industries. However, low graphene coverage, agglomeration, and disordered orientation critically limit their protective performance. Herein, polydopamine-modified graphene was aligned parallel to the substrate via shear-flow-assisted electrodeposition, producing a dense composite coating with high graphene coverage (75.44 %) and volume fraction (30.63 %). This structure enhanced both tribological and anti-corrosion properties: Compared to non-shear conditions, the mass wear rate decreased by 75.0 % (from 0.040 ± 0.012 to 0.010 ± 0.002 mg/(N·m)) and the coefficient of friction (COF) decreased by 65.38 % (from 0.26 ± 0.01 to 0.09 ± 0.01, dry friction, 5 N, RT, vs. Ø 10 mm YG8 alloy ball), attributed to graphene's interlayer slip mechanism (Liu et al., 2020; Guo et al., 2024 [1,2]). The collective contributions of densely packed, ordered coatings' physical barrier effect, electrochemical inhibition, and interfacial strengthening mechanisms reduced corrosion current density by 78.17 % (from 33.90 ± 1.18 to 7.40 ± 1.65 μA/cm² in 3.5 wt% NaCl) compared to non-shear conditions.

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剪切流电沉积控制平行排列的石墨烯-镍涂层具有优异的耐磨损和耐腐蚀性能

石墨烯由于其高模量和化学惰性，是耐磨和耐腐蚀涂层的理想增强材料。ni -石墨烯复合涂料广泛应用于冶金、化工、石油等行业的金属设备防护。然而，低石墨烯覆盖率、团聚和无序取向严重限制了它们的保护性能。通过剪切流辅助电沉积，将聚多巴胺修饰的石墨烯与衬底平行排列，制备出具有高石墨烯覆盖率（75.44%）和高体积分数（30.63%）的致密复合涂层。由于石墨烯的层间滑动机制（Liu et al., 2020; Guo et al., 2024[1,2]），与非剪切条件相比，质量磨损率降低了75.0%（从0.040±0.012到0.010±0.002 mg/(N·m)），摩擦系数（COF）降低了65.38%（从0.26±0.01到0.09±0.01，干摩擦，5 N， RT，与Ø 10 mm YG8合金球相比）。与非剪切条件下相比，致密排列有序的涂层的物理屏障效应、电化学抑制和界面强化机制的共同贡献使腐蚀电流密度降低了78.17%（在3.5 wt% NaCl中从33.90±1.18 μA/cm2降低到7.40±1.65 μA/cm2）。

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来源期刊

Surface & Coatings Technology 工程技术-材料科学：膜

CiteScore

10.00

自引率

11.10%

发文量

921

审稿时长

19 days

期刊介绍： Surface and Coatings Technology is an international archival journal publishing scientific papers on significant developments in surface and interface engineering to modify and improve the surface properties of materials for protection in demanding contact conditions or aggressive environments, or for enhanced functional performance. Contributions range from original scientific articles concerned with fundamental and applied aspects of research or direct applications of metallic, inorganic, organic and composite coatings, to invited reviews of current technology in specific areas. Papers submitted to this journal are expected to be in line with the following aspects in processes, and properties/performance: A. Processes: Physical and chemical vapour deposition techniques, thermal and plasma spraying, surface modification by directed energy techniques such as ion, electron and laser beams, thermo-chemical treatment, wet chemical and electrochemical processes such as plating, sol-gel coating, anodization, plasma electrolytic oxidation, etc., but excluding painting. B. Properties/performance: friction performance, wear resistance (e.g., abrasion, erosion, fretting, etc), corrosion and oxidation resistance, thermal protection, diffusion resistance, hydrophilicity/hydrophobicity, and properties relevant to smart materials behaviour and enhanced multifunctional performance for environmental, energy and medical applications, but excluding device aspects.