Tribological evaluation of HVOF thermal‐spray coatings as a hard chrome replacement

Hard chrome plating has been used in several different applications in industries that require abrasive sliding wear resistance, such as hydraulic pistons, shafts or bearings. However, the increasing environmental and worker safety pressures on electrolytic hard chrome are leading companies to adopt alternatives. The improvements of the high‐velocity‐oxy‐fuel (HVOF) thermal spray process allow the chromium coating replacement with a comparable or superior surface treatment and are more environmentally friendly. This HVOF process, as a flexible dry‐coating technology, avoids high‐volume waste streams and enables a flexible choice of coating material for each application. The cobalt–chromium‐cemented tungsten carbides are some of the easiest materials to spray and the WC‐10Co‐4Cr coatings have demonstrated superior performance over hard chrome with regard to mechanical and tribological properties. In this work, this coating has been deposited with a Sulzer Metco WokaJet‐400 kerosene fuel spray gun, and the spray conditions have been optimized in order to ensure the best properties of the coatings. The mechanical and tribological properties have been evaluated in coatings sprayed with four deposition conditions that involve different gas flow rates. The most wear‐resistant coating is obtained with those HVOF parameters that prevent decarburization of WC particles and, at the same time, allow an adequate agglomerate melting giving a good intersplat adhesion. The results indicate that HVOF‐sprayed WC‐CoCr coatings are a reliable alternative to electrolytic hard chrome (EHC) in the aeronautical industry to coat landing gear components. In particular, in the dry wear tests, the WC‐CoCr coatings outperform hard chrome coatings in wear resistance. Copyright © 2010 John Wiley & Sons, Ltd.     

硫酸盐体系三价铬沉积机理及镀层表征

在新研发的硫酸盐三价铬镀厚铬的镀液体系中, 运用线性扫描伏安法(LSV)和循环伏安法(CV)对三价铬在铜电极表面的电沉积过程进行研究, 并运用X射线荧光测厚仪、扫描电子显微镜(SEM)、X射线能量色散谱(EDS)、X射线衍射仪(XRD)、显微硬度计和Tafel曲线表征铬镀层厚度、形貌、组成、结构、显微硬度及在3.5wt% NaCl溶液中的耐蚀性. 结果表明, 在该体系中三价铬的沉积过程分两步进行(Cr³⁺ + e →Cr²⁺ , Cr²⁺ + 2e → Cr), 第一步得到1个电子, 受电化学过程和扩散过程共同控制, 第二步得到2个电子, 为扩散控制下的不可逆过程; 该镀层为瘤状纳米晶结构, 镀层中含有少量的铁元素(1.10 wt%), 显微硬度达到789.2 Hv, 镀层在3.5wt% NaCl溶液中的腐蚀电位(E_corr)为-0.29 V, 腐蚀电流密度(j_corr)为9.26×10^-5 A·dm^-2.     

Formation of chromium composite electrochemical coatings from sulfate oxalate solutions based on Cr(III)

The mechanism responsible for the inclusion of Al₂O₃ and SiC nanoparticles, the mixture of Nb₂N and Ta₂N (1: 1), MoS₂, Cr₂O₃, and SiO₂ with diverse electric conductivity, hydrophilicity, and resistance to solution components in chromium deposits from the sulfate–oxalate suspension solutions based on Cr(III) was studied. The main factors that determine the formation of chromium composite electrochemical coatings, their composition, and surface morphology were determined. The film on the surface of the growing deposit of the intermediates of the reduction of chromium ions plays the key role in the formation of composite coatings from Cr(III) and Cr(VI) sulfate–oxalate suspension solutions. The film can play the role of a structural mechanical barrier that hinders the incorporation of particles in the deposit, or it can fix the particles on the electrode surface by creating hydroxo bridges with chemisorbed hydroxide compounds on the particle surface.     

Deposition of amorphous chromium layers

Deposition of amorphous chromium-carbon layers is possible from a trivalent chromium electrolyte containing 0.6?mol/l formic acid. The formation of chromium/formic acid complexes inhibits the aging of the electrolyte and the oligomerization. Deposition of a 15–20?μm thick chromium film is possible with DC condition. Thicker films can be deposited with pulse plating using reversed pulse sequences and pulse lengths in the millisecond region. The optimized conditions concerning pulse current densities and pulse times were determined and the composition and morphology of the films investigated.     

Preparation of NiCrBSi‐WC brazed coating and its microstructure characteristics

WC–Ni composite coatings were developed by the powder cloth and the vacuum brazing technology. The wear resistance and the corrosion resistance of the brazed WC–Ni coatings were investigated. The peeling coating samples were prepared by using solder mask during brazing. The microstructures for the powder cloth and for the brazed coatings were characterized by scanning electron microscopy. The distribution of elements in the different area of the brazed coatings was determined by energy dispersive X‐ray maps. It shows that the segregation of chromium carbides occurs during brazing. Apart from penetrating into the interspaces of WC particles, the Ni‐based filler can also infiltrate and spread on the substrate surface. Copyright © 2012 John Wiley & Sons, Ltd.     

Mechanistic study on the effect of PEG molecules in a trivalent chromium electrodeposition process

The mechanism of chromium metal deposition from a trivalent chromium bath containing formic acid and polyethylene glycol 1000 (PEG) was studied on an electrochemical quartz crystal microbalance (EQCM), electrospray ionization mass spectrometry (ESI-MS) and a technique for measuring pH on the cathode surface. Reactions of PEG molecules with trivalent chromium ions and their influence on the plating process of trivalent chromium were investigated. EQCM studies at low trivalent chromium ion concentrations show that chromium electrodeposition occurs via the formation of an adsorption layer on the electrode surface, which is called a cathodic film. Cathodic films hinder the penetration of ions from bulk solution to the cathode surface. In the inner portion of the cathodic film and at the cathode surface, intermediate complexes were formed during the deposition process. ESI-MS revealed that the PEG molecules were stable in a trivalent chromium bath containing potassium formate. During electroplating, the PEG molecules decreased the reductive current of hydrogen compared with solutions without PEG; an effect that was also observed due to the pH on the electrode surface. PEG plays a decisive role in the formation of intermediate compounds during electrodeposition.     

Electrode processes occurring during the electrodeposition of chromium-carbon coatings from solutions of Cr(III) salts with carbamide and formic acid additions

The regularities and possible mechanisms of electrode processes occurring during the electrodeposition of the Cr-C alloy from an electrolyte based on Cr(III) sulfate with carbamide and formic acid as organic components were analyzed. The chromium electrodeposition was found to impose its kinetics on carbon inclusion in the alloy. The mechanism of carbon incorporation in the deposit was assumed to be the chemical interaction of the adsorbed organic particles with highly active chromium adatoms. During the stage discharge of Cr(III) ions to the metal, the rate of the limiting stage Cr(II) + 2e → Cr(0) increased when OH^? or F^? ions were included in the structure of the electrochemically active complex.     

Characterization of deposits build-up on austenitic stainless steel AISI 316L exposed in high purity water system

For the characterization of deposit layers on AISI 316L surfaces in high purity water systems, operating up to 80 °C Mössbauer spectroscopy (ME), scanning electron microscopy (SEM), X-ray fluorescence (XRF) and X-ray photoelectron spectroscopy (XPS) are used. Austenitic steel particles were identified on the surfaces of systems not properly cleaned before start-up. Long exposition of austenitic surfaces to high purity water promotes the build-up, composed by trivalent iron and chromium oxidehydroxides and oxide. The oxidehydroxide phase is located mainly at the solid-water interface, whereas oxide phase is in direct contact with metal. Spheroid-like morphology of particles in these layers and the lack of metal attack suggest that coagulation and crystallization processes are the way for oxide production from existing dissolved species.     

Electrodeposition of composite Ni–B coatings in a stirred heterogeneous system

The formation of composite electrochemical coatings of a nickel matrix with boron microparticles was investigated. Electrolytical nickel–boron layers were deposited on a paraffin-impregnated graphite electrode in a stirred heterogeneous system formed by a Watts-type nickel plating bath and dispersed boron powder particles. The polarisation behaviour of the composite plating bath as a function of the boron particle loading was examined. The effect of deposition conditions, as well as of the amount of boron powder in the plating bath on the boron content in the composite Ni–B coatings, was examined. The composite coating structure was established using scanning electron microscopy and light optical microscopy. The distribution of boron particles in the composite deposits was investigated by dynamic secondary ion mass spectrometry. The boron particles content was determined gravimetrically. The obtained results suggest that the content of incorporated boron particles increases with an increasing amount of boron in the plating bath. The potentiodynamic deposition method is demonstrated to be more suitable for production of composite coatings with a high content of boron particles than the potentiostatic one. Homogeneous distribution of boron particles in the nickel matrix without coagulation or sedimentation was associated with the electrochemical fabrication method in stirred heterogeneous systems.     

穆斯堡尔谱研究电镀镍铁合金层

用穆斯堡尔谱研究了电镀镍铁合金层的形成过程,镀液中Al~(3 ),Mn~(2 ),Cr~(3 ),Zn~(2 )及Cu~(2 )等离子的存在对镀层组成、织构等的影响以及不同铬处理后镍铁镀层的织构和耐蚀性;分析了铬、锰等元素在其中所起的作用;并初步探讨了形成层状结构的原因.     

The electrodeposition of composite coatings: Diversity,applications and challenges

A wide range of coatings can be produced by incorporating particles into an electrodeposit. The matrix may be a metal, conductive polymer or conductive ceramic, whereas the particle can be metallic, polymeric, ceramic or combinations of spheroidal, irregular or layered inclusions. Nanostructured, gradient, multilayer and sandwich layer deposit further widen possibilities. Electrochemical approaches to the deposition of composite coatings offer the benefits of good control over deposition rate (hence thickness), coating composition and deposit properties. Both faradaic electrodeposition and electrophoresis are usually involved. This review focuses on nanosized inclusions in a metal matrix over the last two decades. Interactions between bath composition, particle dispersion, operational variables and resultant deposit properties are poorly documented in the literature. Our understanding of the mechanism of composite deposition remains patchy, despite progress and computer models are scarce. Electrode geometry, electrolyte hydrodynamics and current distribution remain poorly treated. Markets in electronics, surface engineering, aerospace, corrosion protection and electrochemical energy conversion have been stimulated by newer uses for self-cleaning, superhydrophobic and biocompatible surfaces. Challenges to be met by further research and development are prioritised.     

镍-碳化钨微粒复合电沉积机理的研究

研究了在普通镀镍溶液中导电性微粒碳化钨与基质金属镍形成复合镀层的电沉积过程，实验结果表明，导电性的ＷＣ微粒在与Ｎｉ共沉积形成Ｎｉ－ＷＣ复合镀层的过程中，也遵循Ｇｕｇｌｉｅｌｍｉ的两步吸附机理，只是在电极表面，ＷＣ微粒的弱吸附覆盖度与强吸附覆盖度的比值，较非导电性微粒的复合共沉积体系的要小得多。     

Kinetics of electrodeposition of Ni–ZrO<Subscript>2</Subscript> nanocomposite coatings from methanesulfonate electrolytes

Regularities of incorporation of zirconia nanoparticles into a nickel matrix in the course of electrodeposition of Ni–ZrO₂ coatings from methanesulfonate electrolyte are established. The content of the dispersed phase in coatings grows at an increase in its concentration in electrolyte. Moreover, nanocomposites containing a greater amount of zirconia are deposited from the methanesulfonate electrolyte as compared to sulfate electrolyte. This is explained by the greater partial concentration of ZrO₂ in the solution due to enhanced aggregative stability of the dispersed phase in methanesulfonate electrolyte. The mechanism of formation of the composite coating is considered that is based on the concept of particle incorporation into the metal matrix due to the different rates of metal electrodeposition on the electrode surface free of nonmetallic particles and on the electrode surface conditionally occupied by them. A physically substantiated mathematical model is suggested that describes the kinetics of formation of the composite coating that agrees well with the experimental data.     

Electrochemical Processing of Reaction-bonded Ceramic Composite Coatings

Ceramic matrix composite coatings are currently of much interest for application in high-temperature and highly corrosive environments. Formation of ceramic coatings by electrochemical processing is a relatively new mean^[1-2]. It presents several advantages over alternative coating techniques, the thickness and morphology of the deposit can be controlled by the electrochemical parameters, relatively uniform deposits are obtainable on complex shapes, the deposition rate is higher than that using most other methods and the equipment required is of low cost Recently we developed a novel fabrication technique for the production of ceramic/ceramic and ceramic/metal composite coatings by electrochemical processing^[3]. The technique combined two electrochemical deposition methods, electrophoretic deposition (EPD) and electrolytic deposition (ELD), which can produce uniform composite layers of closely controlled thickness on both metallic and ceramic substrates at ambient temperature with inexpensive equipment. However, the main problem associated with electrochemical processing is the difficulty in sintering of the coatings. First, high temperature is required for sintering of the coatings. Secondly, the volume shrinkage of the coatings during sintering leads to the formation of cracks in coatings bonded to metal substrates. So a reaction forming technique, reaction bonding process, also has been developed to produce near net-shape ceramic coatings, which overcome problems caused by the shrinkage of ceramics during sintering.     

Co-WC电极

从钴镀液中添加ＷＣ微粒复合电沉积制备Ｃｏ－ＷＣ镀层,ＷＣ微粒的加入,加快了阴极电化学反应．Ｃｏ－ＷＣ复合电极在碱性溶液中具有优越的电催化析氢性能,并经受了长期间断电解的试验,电极性能稳定     

Characterization of chromate conversion coating on AA7075‐T6 aluminum alloy

Chromate conversion coatings (CCCs) on AA7075‐T6 were characterized using scanning electron microscopy, focused ion beam sectioning and scanning transmission electron microscopy with nano‐electron dispersive spectroscopy line profiling. The thickness and composition of the CCC was different at different locations on the heterogeneous microstructure of AA7075‐T6. The coating formed on the matrix phase was much thicker than that formed on the coarse Al–Cu–Mg, Al–Fe–Cu and Mg–Si intermetallic particles. Nano‐electron dispersive spectroscopy line profiling indicated that the coating on the Al–Fe–Cu particles was similar to the CCC formed on the phase matrix, primarily a chromium oxide. However, the coatings on the Al–Cu–Mg and Mg–Si particles were mixed Al/Mg/Cr oxide and Mg oxide, respectively. The growth of CCC followed a linear‐logarithmic kinetic rate law. The observations of this study support the sol‐gel model of CCC formation. Copyright © 2004 John Wiley & Sons, Ltd.     

离子液体中18-冠醚-6添加剂对三价铬电沉积的影响

在1-丁基-3-甲基咪唑硫酸氢盐（[BMIM]HSO₄）电镀液中,探究了18-冠醚-6添加剂对电沉积铬的影响. 紫外-可见光谱结果表明,18-冠醚-6与Cr³⁺形成配合物,使最大吸收波长发生红移. 循环伏安研究表明,Cr³⁺的还原经历了两步. 18-冠醚-6的添加使Cr³⁺的峰电位和起始还原电位均正移了220 mV. 能谱仪（EDS）结果显示,在18-冠醚-6的作用下镀层中铬含量有所提高. 铬镀层的扫描电子显微镜（SEM）表征结果表明,加入18-冠醚-6后,所得镀层的颗粒变大. 18-Crown-6/CrCl₃/[BMIM]HSO₄/H₂O电镀液中工艺优化的结果为：在温度为50 ^oC、pH值为3.5、电流密度为1200 A·m^-2、电镀时间为1.5 h的最佳工艺条件下,铬镀层的厚度达到72.5 μm,电流效率为42.3%.     

稀土对WC颗粒增强铁基体复合涂层组织结构的影响

采用氩弧熔覆技术在45号钢表面制备一层稀土WC颗粒增强铁基体耐磨复合涂层。通过扫描电镜(SEM)、X射线衍射(XRD)和能谱仪(EDS)等测试分析手段研究了稀土的引入对复合涂层中基体组织及碳化物的影响,并与未加稀土进行了比较。结果表明:引入稀土后,一方面优化了熔覆层组织中碳化物颗粒分布,降低了熔覆层组织中碳化物颗粒的团聚、桥接,且颗粒分布均匀;另一方面改善了熔覆层的组织,细化晶粒,减弱了熔覆过程中产生的树状晶,抑制了WC颗粒的溶解和鱼骨状碳化物的生成。在熔覆层组织中碳化物颗粒相主要有三种存在形式:原始未熔WC颗粒、与基体形成的复式碳化物及在凝固过程中重新结晶的W2C(或WC)。     

Silver particles-modified polysulfonic acid-doped polyaniline layers: electroless deposition of silver in slightly acidic and neutral solutions

Polyaniline layers are produced by electrochemical polymerisation of aniline in the presence of small amounts of poly(2-acryalamido-2-methyl-propane-sulfonic acid) in an inorganic acid solution. Electroactivity and in situ conductance of the obtained polysulfonic acid-doped layers are studied in slightly acidic and neutral solutions. Electroless deposition of silver particles is carried out in silver-EDTA complex ion solutions at pH????.2 and pH????.6 by using the polyaniline layers as reductant. The amount of electroless-deposited silver is studied depending on: polymerisation charge used to synthesize the polymer layer, pH of the plating solution, metal ion concentration and dipping time. SEM shows in all cases a highly non-homogeneous distribution of the metallic phase over the surface, the most protruding fibrillar polymer structures favouring the electroless silver deposition. A linear dependence between amount of the polyaniline material and amount of deposited silver is found for the silver plating solutions with the highest investigated concentration (10?mmol?l^??). At lower concentrations (2.0 and 0.4?mmol?l^??), the same amount of silver becomes deposited on polymer layers with markedly different charges. The electroless deposition of silver in the solutions with lower acidity results in lower amounts of deposited silver at otherwise identical conditions. Effects such as charge transfer within the polymer phase and mass transport in the solution are addressed to explain the observed dependencies of the amount of deposited silver on concentration and pH in the different plating solutions.     

Process aspects of electroless deposition for nickel–zinc–phosphorous alloys

Electroless deposition of Ni–Zn–P thin film was considered as a barrier film on a galvanic Zn or Ni–Zn sacrificial layer in a multicomponent corrosion protective coating on steel. The incorporation of zinc on the chemical composition of electroless Ni–Zn–P coating was studied. The effect of operating conditions such as temperature, pH value and concentration of zinc sulphate was investigated. Some physical characteristics such as morphology, structure, corrosion properties of Ni–Zn–P coatings were assessed in parallel with those of Ni–P. Inclusion of Zn to Ni–P is accompanied by the transformation of the coating structure from amorphous to crystalline. The effect of adding nonionic surfactant to the plating solution on the composition and surface morphologies was also investigated. The results indicate that nonionic surfactant has no effect on the Zn % in the deposit layer, but it affects the surface morphology and improves the corrosion resistance of Ni–Zn–P layers. Copyright © 2005 John Wiley & Sons, Ltd.