Advancing Ni-W/diamond coatings with pulse-brush plating: Insights into particle incorporation and hardness

This study investigates the co-electrodeposition process of Ni-W coatings with diamond particles using the pulse-brush plating technique. This method leverages the high flexibility and localized repair capabilities of brush plating while addressing the challenges associated with particle co-deposition. This study systematically investigates the influence of the brushing technique, particle size, and particle concentration on particle co-deposition behavior. The surface morphology, hardness, and adhesion properties of the coatings are also evaluated. The findings indicate that pulse-brushing enables diamond particles to co-deposit with the Ni-W matrix more effectively than continuous brushing, leading to a significant increase in hardness. The incorporation of 1.5 μm particles at a concentration of 40 g/L resulted in the highest measured hardness of 939.56 ± 25.93 HV_0.1. This sample also exhibited excellent adhesion, with cohesive failure occurring at approximately 30 N and no delamination observed. These experimental results demonstrate that pulse-brushing is highly effective in enhancing particle incorporation and improving the coating's mechanical properties, making it a promising technique for surface engineering and the maintenance of materials requiring high durability and strength.