Corrosion Behavior of Coarse- and Fine-Grain Ni Coatings Incorporating NaH₂PO₄.H₂O Inhibitor Treated Substrates

Plain carbon steel substrates were treated with NaH₂PO₄.H₂O inhibitor for 24 hours and coated with Ni using dc and pulse electrodeposition in standard Watt’s bath. The effect of dc and pulse electrodeposition, on the microstructure and corrosion properties of Ni coatings in 3.5 wt% NaCl solution was studied. The effect of inhibitor on the deposition process and corrosion behavior was also examined. Materials characterization was performed using field emission scanning electron microscopy, cross-sectional scanning transmission electron microscopy, atomic force microscopy, x-ray diffraction and nanoindentation. Experimental results indicated that pulse electrodeposition produced fine grained Ni coatings that showed lower corrosion rate compared to coarse grained dc electrodeposited Ni. Pre-treatment of substrates with inhibitor did not adversely affect the deposition process and adherent Ni coatings were readily developed. The results showed that pulse electrodeposition could be used to produce hard corrosion resistant Ni coatings while the inhibitor treatment yielded enhanced corrosion protection by providing a protective buffer layer between the Ni coating and the substrate.

corrosion; microstructure; Nickel (Ni); electrodeposition; inhibitor; NaH₂PO₄.H₂O; sodium dihydrogen orthophosphate