| LIU Leixiang,REN Lu,JIAN Wei,WANG Hainan.Research Progress of Corrosion Resistant Electroless Nickel-based Coatings[J],54(10):32-46 |
| Research Progress of Corrosion Resistant Electroless Nickel-based Coatings |
| Received:November 18, 2024 Revised:March 27, 2025 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.10.003 |
| KeyWord:electroless plating surface modification corrosion resistance nickel-based coating |
| Author | Institution |
| LIU Leixiang |
College of Mechanical Engineering and Mechanics, Ningbo University, Zhejiang Ningbo , China |
| REN Lu |
College of Mechanical Engineering and Mechanics, Ningbo University, Zhejiang Ningbo , China |
| JIAN Wei |
College of Mechanical Engineering and Mechanics, Ningbo University, Zhejiang Ningbo , China |
| WANG Hainan |
College of Mechanical Engineering and Mechanics, Ningbo University, Zhejiang Ningbo , China |
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| Abstract: |
| Electroless nickel-based coatings have become indispensable in critical industrial applications spanning the electronics sector, energy and petrochemical industries, and aerospace systems, owing to their exceptional corrosion resistance and uniform deposition properties. However, traditional binary alloy coatings such as Ni-P and Ni-B exhibit inherent limitations in corrosion resistance under extreme service conditions including elevated temperature, high pressure, and aggressive acidic/alkaline environments owing to their compositional constraints. The strategic integration of multi-component alloying systems with hierarchical micro-nano architectures has emerged as a transformative paradigm in surface engineering, driving the development of next-generation composite coatings with tailored corrosion-mitigation functionalities. This study provides a systematic examination of corrosion resistance optimization strategies and protective mechanisms in nickel-based electroless composite coatings. In the context of alloying element enhancement, the incorporated metallic constituents enhance coating performance through three fundamental mechanisms involving modifications to deposition behavior, regulation of inter-element interactions, and optimization of corrosion-inhibiting passivation films. The incorporation of transition metals such as tungsten (W) and copper (Cu) modifies the deposition behavior by promoting a transition from conventional co-deposition to induced co-deposition mechanisms. This structural evolution enhances coating uniformity and densification through optimizing nucleation kinetics and reducing defect formation. This structural transformation originates from the induced co-deposition mechanism, which governs the deposition kinetics through precise control of metal ion reduction pathways. The resultant ordered deposition pattern facilitates crystallographic orientation alignment and defect density minimization, thereby substantially enhancing coating integrity. The interfacial metallurgical interactions between alloying elements and matrix constituents (Ni, P) promote the precipitation of corrosion-resistant phases including Ni-W solid solutions and Ni3P intermetallic compounds. These phase transformations simultaneously refine the coating's microstructure through grain boundary stabilization, achieving submicron-scale grain refinement, and enhancing corrosion resistance by establishing protective electrochemical interfaces. The alloying elements enhance the corrosion resistance of the coating by elevating its electrochemical potential and actively participating in the formation of passivation films. This dual mechanism synergistically strengthens the protective oxide layer through compositional refinement and defect passivation, ultimately improving the coating's stability in corrosive environments. Micro-nanoparticles enhance coating performance primarily through pore-filling effects and corrosion path extension mechanisms. Their uniform dispersion within the coating matrix effectively fills microscopic defects to inhibit localized corrosion initiation while simultaneously prolonging corrosive media diffusion pathways via labyrinthine effects, collectively extending the coating's service life. A critical advancement involves the implementation of hybrid particle systems, where precisely engineered particle size distributions enable multiscale synergistic effects. This hierarchical architecture achieves optimized interfacial stress distribution and enhances defect tolerance through particle size gradation mechanisms, thereby elevating the coating's protective performance to superior levels. Process innovations significantly enhance coating performance through targeted microstructural control. Microwave annealing achieves low-temperature densification by leveraging selective dielectric heating mechanisms, preserving metastable phases that contribute to corrosion resistance. Concurrently, ultrasonic-assisted deposition utilizes cavitation-induced microjets to ensure nanoparticle dispersion homogeneity while inhibiting abnormal grain growth, collectively optimizing both mechanical integrity and electrochemical stability. Advanced data processing techniques, exemplified by Response Surface Methodology (RSM), enable multivariate parameter optimization through predictive modeling frameworks. These computational tools establish quantitative correlations between process variables and coating characteristics, facilitating precision control of deposition kinetics while revealing multifactorial dependencies in coating property evolution. These research advancements establish a robust scientific foundation for the development and application of corrosion-resistant nickel-based coatings. Future investigations should prioritize elucidating multi-element synergistic interactions, so as to advance novel nanoscale reinforcement architectures, and refine intelligent manufacturing methodologies to address the escalating global demands for high-performance industrial protection systems. |
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