Wang 2017
Wang 2017
Chuan Wang, Lida Shen, Mingbo Qiu, Zongjun Tian, Wei Jiang
PII: S0925-8388(17)32834-7
DOI: 10.1016/j.jallcom.2017.08.105
Reference: JALCOM 42862
Please cite this article as: C. Wang, L. Shen, M. Qiu, Z. Tian, W. Jiang, Characterizations of Ni-CeO2
nanocomposite coating by interlaced jet electrodeposition, Journal of Alloys and Compounds (2017), doi:
10.1016/j.jallcom.2017.08.105.
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and Astronautics, Yu Dao Street, 210016 Nanjing, China
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* These authors contributed equally to this work
Corresponding author:
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Lida Shen Email: ldshen@nuaa.edu.cn
Fax: +86-025-84892520
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Tel: +86-18951892566
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Abstract: The properties of conventional nickel coatings were improved by preparing
and field emission scanning electron microscopy (FESEM), the corrosion resistance
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appropriate amount of CeO2 NPs, effectively improved coating surface quality and
reduced defects, such as cellular bulges, micropores, and microcracks. The corrosion
current density was reduced from 1.612 to 0.459 µA·cm-2, compared to pure Ni,
which indicated that corrosion resistance was clearly improved. With the introduction
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of interlacing, the coating NP content increased up to 4.76 wt. %, higher than the 4.25
wt. % of conventional jet electrodeposition. The resulting coating surfaces were more
uniform and smooth, and the problem of coating quality deterioration in traditional jet
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interlaced deposition, the corrosion current density was further reduced to 0.349
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Key words: Jet electrodeposition; Interlaced; CeO2; Nanocomposite coating;
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Corrosion resistance
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1 Introduction
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Nanocomposite coatings have excellent properties, such as wear resistance [1–3],
high hardness [4–6], resistance to high temperature oxidation [7–9], and corrosion
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and suspend NP in the solution, and use the electrodeposition method to have these
NP deposit with the metal ion. Rare earth elements have special physical and
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chemical properties, and the rare earth oxide CeO2 has been shown to be effective in
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improving coating hardness, corrosion and wear resistance when it is mixed in the Ni
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solution, which greatly affects composite coating properties. For this reason, Ranjan
Sen [16] has added dispersant into the plating solution, Ignacio Tudela [17] has
introduced an ultrasonic field, and Wei Qiao Liu [18] has combined ultrasonic and
physical stirring. All of those studies have effectively improved or alleviated the
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excellent performance.
advantages of low processing costs, high limit current density, and selective
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processing, the resulting coating has fewer defects and the grains are refined (<20 nm)
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[19–22]. In addition, the circulating plating solution and high-speed jet can play the
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agglomeration. Therefore, jet electrodeposition shows certain advantages in the
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preparation of nanocomposite coatings, but, at present, related studies are still
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relatively scarce at home and abroad. Yihao Wang [23] has prepared Ni-SiO2
composite coatings by jet electrodeposition with online friction; the prepared coating
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and nano-CeO2, in this paper, a kind of discontinuous deposition with cathode rotation
and interlacing technology was proposed and used in the preparation of Ni-CeO2
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state of the deposition surface below the nozzle and avoid continuous, preferential
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deposition in certain areas. Thus, the coating was able to grow homogeneously, the
NPs distributed uniformly in the coating, coating defects reduced, and corrosion
chemical deposition, this method has more simple equipment and technology, the
2 Experimental
The experimental device is shown in Fig. 1. The plating solution is pumped into
the anode chamber from the plating bath and then sprayed onto the cathode workpiece.
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The anode chamber is filled with nickel (Ni) beads to maintain the Ni2+ content in the
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system, which consists of three motors. The x-axis motor controls the nozzle for
smooth traverses; the y-axis motor drives the nozzle vertical movement, adjusting the
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machining gap; and the z-axis motor controls the workpiece rotation through a pair of
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bevel gear transmissions. Thus, cathode rotation with interlaced deposition is realized.
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2.2 Cathode rotation device
motor drives the fixture together with the workpiece, rotating in the x/z plane through
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a pair of bevel gear transmissions. Wherein the bevel gears and the gear base are
printed via 3D printer .Through early experimental research, it was found that the
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microstate of the substrate surface was random, which led to the random influence of
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electrodeposition process, the nozzle moves back and forth along the x-axis. After a
certain time, the deposition power is turned off and the z-axis motor drives the
workpiece rotate 90 degrees. Subsequently, the power is turned on, completing the
deposition on the other direction. This process is repeated until the desired
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2.3 Pretreatment
Graphite has the advantages of good conductivity and easy pretreatment, and it is
also easy to strip clean for coating tests. Thus, graphite, with a dimension of
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20×20×3mm, was selected as the substrate. Before an experiment, the graphite
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substrate was polished sequentially with #1–#6 sandpaper to remove the surface
texture and then subjected to ultrasonic cleaning in alcohol and deionized water.
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The NPs used were CeO2 powder, with particles 20 nm diameter and 99.99%
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pure. NPs were added to electroplating solution quantitatively and uniformly
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dispersed by ultrasonic vibration of the solution for 60 min and magnetic stirring for 2
considered one layer. The number of nozzle traversing deposition in this experiment
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was 441. Considering earlier studies on the effects of interlaced deposition on pure Ni
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coating properties, it was found that, for an interlaced coating layer, the nozzle
layers, the coating surface was relatively flat and with few defects. Therefore, for the
interlaced composite coating in this paper, the interlaced layer is 63. Two experiments
shown in Table 1.
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investigate the surface morphologies of the composite coatings. The weight
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percentage of CeO2 in the coatings as well as elemental line scans was determined
with Oxford INCA energy dispersive X-ray spectroscopy (EDS) coupled to the SEM.
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The coatings were analyzed by X-ray diffraction (XRD) spectrometer (D/max
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2500VL/PC) operated at 40kV and 300mA with Cu-Kα radiation (λ= 1.5406 Å) to
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determine the phase composition and the crystallite size.
without agitation at the room temperature. The reference electrode was a saturated
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calomel electrode (SCE), and the counter electrode was a platinum electrode. The
samples were immersed in the corrosive medium to attain open circuit potential (Eocp)
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about 30 min. Then the potentiodynamic sweeping was performed in the potential
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range of ±500 mV with respect to the Eocp by 1 mV/s sweeping rate. Electrochemical
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impedance spectra (EIS) were performed in an applied frequency ranged from 105 Hz
using FESEM. As can be seen from Fig. 3a, there were many large cellular (cell-like)
bulges on the coating surface and even overlapping growth between adjacent bulges.
This is because the actual substrate surface inevitably had a large number of micro
bulges, and the formation of the preferential nucleus could also cause irregularities on
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the cathode surface. Under a relatively strong electric field, because of point discharge
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effects, the bulges showed greater curvature, much denser equipotential surfaces, and
the electric field strength was significantly enhanced [20]. This caused the coating to
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grow preferentially at micro bulges, thus forming larger cellular bulges. Such bulges
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produced shielding effects on the surrounding small electric field, as shown in Fig. 4,
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thereby inhibiting the growth of surrounding small bulges and affecting coating
uniformity. A coating growth schematic diagram is shown in Fig. 5a. As shown in Fig.
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3b, the numbers and size of the cellular bulges was significantly reduced after adding
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5 g/L CeO2 NPs into the solution, and, also, a small amount of NPs were observed on
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the surface (small, black spots in the figure). When the NP content was increased to
15 g/L, as shown in Fig. 3c, the cellular bulges almost disappeared, the coating
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surface was relatively smooth, and the NPs distributed uniformly and densely on the
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surface. This is because increased NP provided more growth points for deposition that
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then promoted uniform coating growth. However, when the particle content was
bulges easily formed, which affected coating quality, as shown in Fig. 3d.
coating with interlacing are shown in Fig. 6. In contrast to Fig. 3a, cellular bulges of
interlaced pure Ni coating in Fig. 6a were clearly reduced and the surface was smooth.
and transposition, the distribution of electric field on the surface under the nozzle was
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altered. The growing points, shielded in last layer had a greater chance of breaking
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through the shield and re-growing (Fig. 5b). The growth capacity of growing points
on the whole deposition surface was fully developed, making the deposition more
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uniform. Although a solution NP content of 20 g/L facilitated NP agglomeration and
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cellular bulge formation, due to the advantages of interlaced deposition’s
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improvement in point discharge and shielding effects, cellular bulges did not appear
in coating as Fig. 3d, instead it remained smooth, as shown in Fig. 6c. Moreover, NPs
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To indicate the distribution of CeO2 NPs across the coating thickness, the
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elemental line scans for Ce, O and Ni are shown on the cross sectional SEM image in
Fig. 7. A quite uniform distribution for elemental Ce and therefore CeO2 is obtained.
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The cross sectional SEM image also indicates that interlayers adhere well without
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segregation.
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spots in Fig. 6b). The EDS spectrum showed Ce peaks indicating the presence CeO2
Ni-CeO2 composite coating was successfully prepared. The black spots observed on
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coatings increased with the increase of NP concentration in the solution, and reached
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the highest value at 4.25% under 15 g/L. However, CeO2 coating content decreased as
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the concentration was further increased to 20 g/L. This is because, with more NPs in
solution, more NPs weakly adsorbed onto the substrate surface, resulting in more
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chances to convert to strong absorbance and be captured by deposited Ni. However,
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when the solution NP content was too high, on one hand, NPs agglomerated, which
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hindered composite deposition [11]. On the other hand, a large number of NPs were
injected onto the cathode, colliding with weakly adsorbed NPs on the cathode surface
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and converting them back to the free state and thus decreasing the NPs embedded in
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the coating.
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The NP content in interlaced composite coatings was generally higher than that
of non-interlaced coatings and the maximum in the former reached 4.76%; this trend
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was more obvious with increased solution CeO2 concentrations. The reason for this is
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that the surface of the interlaced coating was more uniform, which, in turn, affected
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the uniform distribution of electric field, and this was beneficial for NP to deposit on
discharge effects, large bulges shielded small electrical fields, which prevented some
weakly adsorbed NPs from being strongly adsorbed in time. These residual weakly
adsorbed NPs were impacted by high-speed jet particles and converted back to free
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state instead. The higher the solution NP content was, the more obvious the effect was.
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interlaced coatings was much less than that of traditional jet electrodeposition.
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3.2 Microstructure
Fig. 10 shows the X-ray diffraction patterns of pure Ni and Ni-CeO2 composite
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coatings. A comparison with the Ni standard pattern shows that the structure was
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face-centered cubic structure, the corresponding crystal plane of the diffraction peaks
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of the coating were (111), (200), (220), (311), and (222). As shown in Fig. 10a, the
growth of Ni coatings was dominated by the (111) crystal surface and, with NP
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addition, the (111) crystal surface was slightly enhanced, other crystal surfaces,
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especially (200) and (311) decreased. The absence of CeO2 diffraction peak is that the
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Fig. 10b shows the partially enlarged details of the (111) peak, it is obvious that
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the (111) peak shifts to left at a small angle after CeO2 NP addition, this shifting
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implies that the crystal lattice constant became larger. The reason for this effect could
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be that the addition of NPs resulted in residual (macro) stresses in coating, thereby
surface free energy and strain energy [2,24], a possible reason for the
above-mentioned small changes in diffraction peaks intensity might have been that
NPs affected surface free energy and strain energy in coating. Interlaced deposition
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increased the NP embedded in the coating, therefore, the diffraction peak angle of the
13.53nm. When adding 15 g/L CeO2, the grain size of nanocomposite coating
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decreased to 11.7nm, which is a little greater than that for interlaced composite
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coating of 10.9nm. This indicates that the incorporation of reinforcing particles
promotes the nucleation rate and demote the grain growth, thus the grain size was
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refined, which is corresponded to existing researches [14,26].
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3.3 Corrosion resistance
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Fig. 11a shows the potentiodynamic polarization curves of Ni and Ni-CeO2
coatings in 3.5 wt% NaCl solution. The corrosion potential Ecorr and current density
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and lower corrosion current density than those of pure Ni coatings, indicating better
corrosion resistance. With increased NP content, the corrosion resistance was further
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improved, achieving the best at 15 g/L. Here, the corrosion current density decreased
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from 1.612 µA·cm-2 for pure Ni coating to 0.459 µA·cm-2 for Ni-CeO2 coating.
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However, when the concentration reached 20 g/L, the NP embedded in the coating
density, but it was still lower that of pure Ni coating. Comparing sample d, d’ and e,
e’, the current density was further reduced after the introduction of interlacing.
Electrochemical impedance spectra (EIS) in 3.5 wt% NaCl solution were obtained and
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shown as Nyquist plots in Fig. 11b, it is obvious that the capacitive loop radius of the
composite coating was larger than that of pure Ni coatings, while the interlaced
coating showed the largest capacitive loop radius, which indicated higher polarization
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greatly improved coating corrosion resistance, which was even further enhanced in
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interlaced composite coatings.
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immersed in 3.5 wt% NaCl solution for 96 h. The corrosive surface morphology of Ni
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and Ni-CeO2 coatings are shown in Fig. 12. Pure Ni coating in Fig. 12a appeared
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larger corrosion pits in larger cellular bulges, suffering severe corrosion because of
defects in the cellular bulges where the coating was not dense, providing channels for
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corrosive chloride ions. After adding NPs, corrosion was greatly reduced, with the
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size of corrosion pits reduced to ~200 nm, as shown in Fig. 12b. After the
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introduction of interlacing, as shown in Fig. 12c, the coating surface is basically intact;
cellular bulges were easily produced. With continued deposition, large cellular bulges
grew faster and faster and finally submerged smaller bulges, such that many pores
were formed between large cellular bulges. This result seriously affected coating
compactness and uniformity, resulting in large bulges that easily allowed severe
With NPs added to the electrodeposition solution, on one hand, they provided
many growth points for deposition and decreased the appearance of cellular bulges,
such that the coatings were more homogeneous and compact. On the other hand, as an
inert rare earth composite phase, CeO2 NPs were uniformly distributed on the surface
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of the coating, which could effectively reduce the metallic area exposed to the
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corrosive medium, and then the corrosion potential shifted to more positive values.
Grain size and the density of grain boundaries is another important factor affecting
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corrosion properties. The grain boundaries due to their higher energy levels are more
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susceptible to corrosion compared to inter-crystalline parts of material. Therefore, the
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corrosion procedure is facilitated by decreasing the grain size and increasing the
boundaries and since CeO2 is more positive than Ni matrix, micro-galvanic cells were
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formed at particle/matrix interfaces. Thus the corrosion mechanism was changed from
inert rare earth composite phase, CeO2 NPs were effectively absorbed, filling pores,
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micro cracks, and other defects, and thus blocking the permeation of corrosive ions
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from corrosive medium. Due to all those above mentioned factors, corrosion
coatings was further improved and the embedded NPs increased, thus further
4 Conclusions
more growth points for deposition and efficiently improved coating surface quality.
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shielding effects, thus yielding coatings more homogeneous and smooth. In addition,
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interlacing alleviated to some extent the problem of coating quality deterioration in
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(2) With increased NP concentration in solution, more NPs were embedded in
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coatings, showing up to 4.25%. However, when the concentration was too high, the
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NP content decreased significantly. Interlaced composite deposition eased this
problem to some extent, and under the same conditions, the NP embedded in
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interlaced coatings were higher than that of conventional jet electrodeposition. The
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(4) Ni-CeO2 composite coatings exhibited greatly improved corrosion resistance, with
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the corrosion current density decreased to 0.459 µA·cm-2, compared to 1.612 µA·cm-2
in pure Ni coatings, and interlacing technology further reduced this to 0.349 µA·cm-2.
Acknowledgements
(grant No. 51475235 and No. 51105204). We also extend our sincere thanks to all
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Fig. 3.Surface morphology of pure Ni coating and Ni-CeO2 nanocomposite coating (b,
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5 g/L; c, 10 g/L; d, 20 g/L)
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Fig. 4.Cellular bulges’ effect on current lines
Fig. 5.Coating growth (a) Traditional jet electrodeposition (b) Interlacing jet
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electrodeposition
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Fig. 6.Surface morphology of (a) Interlaced pure Ni coating and Ni-CeO2
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nanocomposite coating (b, 15 g/L; c, 20 g/L)
Fig. 7.Elemental line scans of the Ni, Ce and O on the cross sectional SEM image
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Fig. 11 (a) Potentiodynamic polarization curves and (b) Nyquist plots of coatings in
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Fig. 12.Surface morphology after corrosion (a. Pure Ni, b. 15g/L CeO2, c. 15g/L
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(a) Schematic diagram (b) Scene Photograph
Fig. 1.Experiment device
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Fig. 3.Surface morphology of pure Ni coating and Ni-CeO2 nanocomposite coating (b,
5 g/L; c, 10 g/L; d, 20 g/L)
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(a) Traditional jet electrodeposition
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(b)Interlacing jet electrodeposition
Fig. 5.Coating growth
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Fig. 7.Elemental line scans of the Ni, Ce and O on the cross sectional SEM image.
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Fig. 9.Approximate deposited nanoparticles content as a function of their
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concentration in the electrodeposition solution.
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Fig. 11 (a) Potentiodynamic polarization curves and (b) Nyquist plots of coatings in
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3.5 wt% NaCl solution.
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Fig. 12.Surface morphology after corrosion (a. Pure Ni, b. 15g/L CeO2, c. 15g/L
CeO2 with interlacing)
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Tables
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C7H5O3NS 5 g/L
CeO2 0,5,10,15,20 g/L
Temperature 50℃
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Current density 100A/dm2
Traverse times 441
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Table 2 Electrochemical data of Ni and Ni-CeO2 coatings.
CeO2
Samples Interlacing Ecorr/V icorr/µA·cm-2
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addition(g/L)
a 0 No -0.275 1.612
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b 5 No -0.251 0.781
c 10 No -0.244 0.594
d 15 No -0.223 0.459
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e 20 No -0.263 0.755
d’ 15 Yes -0.213 0.349
e’ 20 Yes -0.235 0.564
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Highlights:
1. A cathode rotation and interlaced jet electrodeposition method was developed.
2. Interlaced composite coatings were more uniform and compact with fewer
defects.
3. Interlacing could improve coating deterioration due to nanoparticles aggregation.
4. Interlacing increased particle content embedded in coating from 4.25% to 4.76%.
5. Coating corrosion properties were improved by incorporation of CeO2.
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