目的 弥补6061铝合金在强腐蚀、高磨损工况下的性能短板,同时维持其导热性能,提升铝合金表面综合性能。方法 在6061铝合金表面采用脉冲电沉积技术制备Ni-Cu镀层;通过L16正交实验探究电流密度、占空比和频率对镀层性能的影响规律。结合改进人工蜂鸟算法（MOAHA）与CRITIC-TOPSIS评价方法开展工艺参数多目标优化。引入Fuch混沌映射优化初始种群分布,结合改进拥挤距离计算方法改进原始人工蜂鸟算法,采用CRITIC-TOPSIS法筛选出最优工艺参数。结果 实验表明,优化参数（电流密度3.87 A/dm2、占空比75%、频率262 Hz）制备的YH镀层综合性能显著优化：硬度为273.70HV0.05,导热系数为11.11 W/(m·K),自腐蚀电流密度为1.21 μA/cm2,磨损率为1.092×10-5 mm3/(N·m),并且微观结构致密均匀。结论 改进人工蜂鸟算法与CRITIC-TOPSIS评价方法结合的多目标优化策略,可有效平衡Ni-Cu镀层耐磨、耐蚀与导热性能的耦合矛盾;优化后制备的Ni-Cu镀层综合性能优异,能有效弥补6061铝合金在严苛工况下的性能缺陷,为铝合金表面防护提供了新的技术路径。
Abstract
To address the performance coupling contradictions between corrosion resistance, wear resistance, and thermal conductivity of 6061 aluminum alloy in harsh service environments, the work aims to propose a multi-objective optimization strategy for the fabrication of pulse electrodeposited Ni-Cu coatings. An improved multi-objective Artificial Hummingbird Algorithm (MOAHA) was combined with the CRITIC-TOPSIS decision-making framework to enhance the comprehensive surface properties of the alloy without compromising its inherent lightweight and thermal conductivity advantages. To capture complex non-linear relationships within the electrodeposition process, an orthogonal experimental array was used to quantify the effects of current density (1.5-4.5 A/dm2), pulse duty cycle (30%-75%), and pulse frequency (200-1 400 Hz). The resultant key coating properties were extensively characterized through X-ray diffraction (XRD), microhardness testing, tribological testing, and electrochemical polarization measurements. To overcome the limitations of insufficient convergence and poor population diversity in the original Artificial Hummingbird Algorithm (AHA), two key innovations were introduced in this work. Firstly, Fuch chaotic mapping optimized the initial population distribution, ensuring uniform parameter space coverage and preventing local optima. Secondly, an improved crowding distance mechanism based on Euclidean metrics enhanced the diversity and uniformity of the Pareto optimal front. The CRITIC-TOPSIS then filtered the Pareto solution set. CRITIC objectively quantified performance index weights by evaluating index variability and information redundancy, eliminating subjective biases. Following this, TOPSIS ranked candidate solutions based on their relative proximity to theoretically positive and negative ideal solutions. The globally optimal parameters were determined as a current density of 3.87 A/dm2, a duty cycle of 75%, and a pulse frequency of 262 Hz. The optimized coating (designated as YH) synthesized under these conditions exhibited enhancements in comprehensive properties, yielding a microhardness of 273.70 HV0.05, a sustained high thermal conductivity of 11.11 W/(m·K), a low self-corrosion current density of 1.21 μA/cm2, and an exceptional wear rate of 1.092×10-5 mm3/(N·m). This optimized design was validated against the optimal coating derived from the orthogonal experiments (NC16: 4.5 A/dm2, 75%, 200 Hz) and a randomly generated control (RC: 2.81 A/dm2, 69.13%, 244.14 Hz). Quantitatively, the YH coating's wear rate was 6.3% and 31.3% lower than NC16 and RC. Concurrently, its self-corrosion current density was reduced by 34.0% compared to NC16 and 83.0% compared to RC, preserving excellent thermal conductivity. SEM and EDS characterizations unveiled the underlying physical mechanisms. The structural evolution of the YH coating was characterized by a highly dense, uniform, and structurally refined cauliflower-like columnar morphology. EDS analyses confirmed this improvement originated from microstructural refinement rather than macroscopic compositional changes, as elemental distribution remained stable (approximately 94at.% Ni and 6at.% Cu). Governed by the Hall-Petch effect, substantial grain refinement impedes dislocation mobility under stress, significantly augmenting microhardness and wear resistance. Furthermore, the highly dense morphological structure dramatically minimizes micro-defects and grain boundary gaps, thereby reducing permeation channels for corrosive media. This physical barrier effect fundamentally suppresses electrochemical corrosion kinetics, leading to outstanding corrosion resistance. Ultimately, this methodology effectively resolves the complex performance coupling contradictions inherent in multi-component coatings, offering a data-driven, reliable technical route for the advanced design and performance enhancement of protective coatings on aluminum alloys.
关键词
Ni-Cu镀层 /
脉冲电沉积 /
6061铝合金 /
改进人工蜂鸟算法 /
多目标优化 /
CRITIC-TOPSIS法
Key words
Ni-Cu coatings /
pulse electrodeposition /
6061 aluminum alloy /
improved artificial hummingbird algorithm /
multi-objective optimization /
CRITIC-TOPSIS method
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