Synthesis and Characterization of Functionally Gradient Ni-ZrO2 Composite Coating

Abstract

For the first time, functionally ZrO₂ content graded Ni-ZrO₂ composite coating has been successfully co-electrodeposited from a bath with gradually increasing stirring rate. For this, different composite coatings were electroplated in the same bath with different stirring rates to find the optimum stirring rate in which the maximum content with uniform distribution of ZrO₂ particles in the coating can be achieved. To produce ZrO₂ content graded Ni-ZrO₂ composite coating, the stirring rate was continuously increased from 0 to optimum value. By increasing of ZrO₂ particles content, the microhardness increases from interface towards the surface of the coating. The results of wear resistance measurements, Electrochemical impedance spectroscopy and potentiodynamic polarization test revealed that wear and corrosion resistances of functionally graded Ni-ZrO₂ (FGNZ) is higher than that of ordinary Ni-ZrO₂ (ONZ) composite coating. This result has been attributed to lower mechanical mismatch between coating and substrate in the functionally graded composite coating with respect to the uniformly distributed one.