Microstructure, wear and corrosion resistances of Ni–ZrO2–CeO2 nanocoatings

This study focused on the fabrication of Ni, Ni–ZrO2 and Ni–ZrO2–CeO2 nanocoatings using ultrasonic pulse electrodeposition. The research delved into examining the surface morphology, microhardness, abrasion, and corrosion resistance of these coatings. The results indicated that the Ni coatings displayed coarse grains and an irregular structure. Among the three, the Ni–ZrO2–CeO2 nanocoatings exhibited the most dense, flat and fine microstructure among all three coatings, and the average diameters of Ni grains, ZrO2 and CeO2 nanoparticles were 68.6 nm, 21.1 nm and 23.4 nm, respectively. The Ni, Ni–ZrO2, and Ni–ZrO2–CeO2 nanocoatings displayed high micro-hardness values, measuring an average of 363.1 Hv, 421.6 Hv, and 543.8 Hv, respectively. Moreover, the friction coefficient of Ni–ZrO2–CeO2 nanocoatings was approximately 0.31. When exposed to a 3.5wt.% NaCl solution at room temperature, the Ni–ZrO2–CeO2 nanocoatings displayed minimal corrosion damage, exhibiting the lowest corrosion rate of 0.06 mm/year compared to the other coatings. The incorporation of ZrO2 and CeO2 nanoparticles in the Ni–ZrO2–CeO2 coating led to grain size reduction and a more uniform, compact microstructure, contributing to enhanced corrosion resistance when compared to both Ni and Ni–ZrO2 coatings.