Crack Development of Electroplated NiW Alloys and their Wettability and Tribological properties

Jidsucha  DARAYEN; Suwat  PLOYPECH; Martin  METZNER; Claudia Beatriz dos  SANTOS; Petch JEARANAISILAWONG; Yuttanant BOONYONGMANEERAT

doi:10.55713/jmmm.v35i4.2376

ผู้แต่ง

Jidsucha DARAYEN Metallurgy and Materials Science Research Institute, Chulalongkorn University, Bangkok, 10330, Thailand; Faculty of Engineering, Thammasat School of Engineering, Thammasat University, Pathum Thani 12120, Thailand
Suwat PLOYPECH Nanoscience and Technology, Graduate School, Chulalongkorn University, Bangkok, 10330, Thailand
Martin METZNER Fraunhofer Institute for Manufacturing Engineering and Automation, Stuttgart, 70569, Germany
Claudia Beatriz dos SANTOS Fraunhofer Institute for Manufacturing Engineering and Automation, Stuttgart, 70569, Germany
Petch JEARANAISILAWONG Department of Mechanical and Aerospace Engineering, Faculty of Engineering King Mongkut’s University of Technology North Bangkok, Bangkok, 10800, Thailand
Yuttanant BOONYONGMANEERAT Metallurgy and Materials Science Research Institute, Chulalongkorn University, Bangkok, 10330, Thailand

DOI:

https://doi.org/10.55713/jmmm.v35i4.2376

คำสำคัญ:

Ni-W coating, Cr replacement, Wear resistance, Crack density, Wettability

บทคัดย่อ

This study investigates how sodium tungstate concentration (20–46 wt.%) and current density (40–60 A/dm²) affect the microstructure, wettability, mechanical properties, and tribological behavior of electrodeposited Ni-W coatings. Results show that increasing current density markedly raises crack density (from <100 to >400 cracks/cm²), while tungstate concentration has minimal effect. XRD confirms Ni-W solid solution formation, with higher tungsten content refining grains and increasing hardness—peaking at 900 HV at 50 A/dm² (an 80% rise from 500 HV at 40 A/dm²). However, excessive stress at 60 A/dm² leads to microcracking and hardness plateauing (~650–700 HV). Higher crack density improves wettability (contact angle ~17°), enhancing lubricant retention. Wear tests reveal that coatings with controlled microcrack networks perform better, with wear rates dropping by up to 60% in lubricated conditions. These findings highlight the potential of fine-tuning electroplating conditions to optimize Ni-W coatings as durable, high-performance, and environmentally friendly alternatives to chromium coatings, especially for aerospace, automotive, and industrial applications.

Downloads

Download data is not yet available.

เอกสารอ้างอิง

H. Kir, and S. Apay, "Effect of hard chrome plating parameters on the wear resistance of low carbon steel," Materials Testing, vol. 61, pp. 1082-1086, 2019. DOI: https://doi.org/10.3139/120.111423

L. Fedrizzi, S. Rossi, F. Bellei, and F. Deflorian, "Wear-corrosion mechanism of hard chromium coatings," Wear, vol. 253, pp. 1173-1181, 2002. DOI: https://doi.org/10.1016/S0043-1648(02)00254-5

M. Mekicha, M. Rooij, D. T. A. Matthews, C. Pelletier, L. Jacobs, and D. J. Schipper, "The effect of hard chrome plating on iron fines formation," Tribology International, vol. 142, p. 106003, 2019. DOI: https://doi.org/10.1016/j.triboint.2019.106003

J. Li, C. Yao, Y. Liu, D. Li, B. Zhou, and W. Cai, "The hazardous hexavalent chromium formed on trivalent chromium conversion coating: The origin, influence factors and control measures," Journal of hazardous materials, vol. 221-222, pp. 56-61, 2012. DOI: https://doi.org/10.1016/j.jhazmat.2012.04.004

A. Kaparwan, "Hexavalent chromium induced toxicity in nature and living beings," International Educational Scientific Research Journal vol. 9, pp. 1-9, 2023.

M. R. Shaibur, "Heavy metals in chrome-tanned shaving of the tannery industry are a potential hazard to the environment of Bangladesh," Case Studies in Chemical and Environmental Engineering, vol. 7, p. 100281, 2023. DOI: https://doi.org/10.1016/j.cscee.2022.100281

M. M. Mennucci, R. Montes, A. C. Bastos, A. Monteiro, P. Oliveira, J. Tedim, and M. G. S. Fe, "Nanostructured Black nickel coating as replacement for black Cr(VI) finish," Applied Sciences, vol. 11, no. 9, p. 3924, 2021.. DOI: https://doi.org/10.3390/app11093924

M. Arnaudova, E. Lefterova, and R. Rashkov, "Corrosion behavior of electrodeposited nickel-based coatings with W, Mo, and TiOx," Journal of Solid State Electrochemistry, vol. 28, no. 5, pp. 1657-1670, 2024. DOI: https://doi.org/10.1007/s10008-023-05696-3

S. Lu, F. Roudet, A. Montagne, T. Coorevits, G. Guilbert, A. Mouftiez, D. Betrancourt, and D. Chicot, "Vickers hardness of NiW coating as a potential replacement for Cr-VI: A methodology to consider size effect and tip defect in classical microindentation," Surface and Coatings Technology, vol. 447, p. 128812, 2022. DOI: https://doi.org/10.1016/j.surfcoat.2022.128812

M. Srivastava, C. Anandan, and W. V.K, "Ni-Mo-Co ternary alloy as a replacement for hard chrome," Applied Surface Science, vol. 285, pp. 167-174, 2013. DOI: https://doi.org/10.1016/j.apsusc.2013.08.025

P. Trebuňa, D. Kottfer, M. Pekarcikova, A. Petrikova, R. Popovic, F. Rehak, and P. Ciznar, "Evaluating the Replacement of galvanic Cr coatings," Polish Journal of Environmental Studies, vol. 27, 2018. DOI: https://doi.org/10.15244/pjoes/76679

M. H. Allahyarzadeh, M. Aliofkhazraei, A. R. Rezvanian, V. Torabinejad, and A. R. Sabour Rouhaghdam, "Ni-W electro-deposited coatings: Characterization, properties and applications," Surface and Coatings Technology, vol. 307, pp. 978-1010, 2016. DOI: https://doi.org/10.1016/j.surfcoat.2016.09.052

X. Zhang, J. Qin, M. Kumar Das, R. Hao, H. Zhong, A. Thueploy, S Limpanart, Y. Boonyongmaneerat, M. Z. Ma, and R. Liu, "Co-electrodeposition of hard Ni-W/diamond nanocomposite coatings," Scientific Reports, vol. 6, no. 1, p. 22285, 2016. DOI: https://doi.org/10.1038/srep22285

Y. Ko, G. Chang, and J. H. Lee, "Nickel tungsten alloy electroplating for the high wear resistant materials applications," Solid State Phenomena, vol. 124-126, pp. 1589-1592, 2007. DOI: https://doi.org/10.4028/www.scientific.net/SSP.124-126.1589

N. Eliaz, T. M. Sridhar, and E. Gileadi, "Synthesis and characterization of nickel tungsten alloys by electrodeposition," Electrochimica Acta, vol. 50, no. 14, pp. 2893-2904, 2005. DOI: https://doi.org/10.1016/j.electacta.2004.11.038

T. J. Rupert, and C. A. Schuh, "Sliding wear of nanocrystalline Ni–W: Structural evolution and the apparent breakdown of Archard scaling," Acta Materialia, vol. 58, no. 12, pp. 4137-4148, 2010.. DOI: https://doi.org/10.1016/j.actamat.2010.04.005

S. Liza, N. Ohtake, H. Akasaka, and J. M. Munoz-Guijosa, "Tribological and thermal stability study of nanoporous amorphous boron carbide films prepared by pulsed plasma chemical vapor deposition," (in eng), Science and Technology of Advanced Materials, vol. 16, no. 3, p. 035007, 2015. DOI: https://doi.org/10.1088/1468-6996/16/3/035007

M. Donten, "Bulk and surface composition, amorphous structure, and thermocrystallization of electrodeposited alloys of tungsten with iron, nickel, and cobalt," Journal of Solid State Electro-chemistry, vol. 3, no. 2, pp. 87-96, 1999. DOI: https://doi.org/10.1007/s100080050133

M. Benaicha, M. Allam, A. Dakhouche, and M. Hamla, "Electro-deposition and Characterization of W-rich NiW Alloys from Citrate Electrolyte," International Journal of Electrochemical Science, vol. 11, pp. 7605-7620, 2016. DOI: https://doi.org/10.20964/2016.09.17

I. Mizushima, P. Tang, H. Hansen, and M. Somers, "Development of a new electroplating process for Ni–W alloy deposits," Electrochimica Acta, vol. 51, pp. 888-896, 2005. DOI: https://doi.org/10.1016/j.electacta.2005.04.050

S. Ploypech, M. Metzner, C. dos Santos, P. Jearanaisilawong, and Y. Boonyongmaneerat, "Effects of crack density on wettability and mechanical properties of hard chrome coatings," Transactions of the Indian Institute of Metals, vol. 72, 2019. DOI: https://doi.org/10.1007/s12666-018-01553-4

A. J. Detor, and C. A. Schuh, "Tailoring and patterning the grain size of nanocrystalline alloys," Acta Materialia, vol. 55, no. 1, pp. 371-379, 2007.. DOI: https://doi.org/10.1016/j.actamat.2006.08.032

C. N. Panagopoulos, E. P. Georgiou, D. A. Lagaris, and V. Antonakaki, "The effect of nanocrystalline Ni-W coating on the tensile properties of copper," AIMS Materials Science, vol. 3, no. 2, pp. 324-338, 2016,. DOI: https://doi.org/10.3934/matersci.2016.2.324

Y. Xu, D. Wang, M. Sheng, W. Huihua, R. Guo, S. Sheng, and X. Duan, "Study on internal stress of electrodeposition layer of high tungsten Ni-W alloy," SSRN Electronic Journal, p. 4243337, 2022. DOI: https://doi.org/10.2139/ssrn.4243337

J. Zhang, P. A. Korzhavyi, and J. He, "First-principles modeling of solute effects on thermal properties of nickel alloys," Materials Today Communications, vol. 28, p. 102551, 2021. DOI: https://doi.org/10.1016/j.mtcomm.2021.102551

G. Dosovitskiy, S. V. Samoilenkov, A. R. Kaul, and D. Rodionov, "Thermal expansion of Ni-W, Ni-Cr, and Ni-Cr-W alloys between room temperature and 800 degrees C," International Journal of Thermophysics - INT J THERMOPHYS, vol. 30, pp. 1931-1937, 2009. DOI: https://doi.org/10.1007/s10765-009-0660-9

Y. Xu, D. Wang, M. Sheng, and H. Wang, "Internal stress of high tungsten content Ni-W alloy coatings," Surface Engineering, vol. 39, no. 6, pp. 769-779, 2023. DOI: https://doi.org/10.1080/02670844.2023.2257855

C.-Y. Hui, T. Liu, and M.-E. Schwaab, "How does surface tension affect energy release rate of cracks loaded in Mode I?," Extreme Mechanics Letters, vol. 6, pp. 31-36, 2016. DOI: https://doi.org/10.1016/j.eml.2015.11.002

Y. Boonyongmaneerat, K. Saengkiettiyut, S. Saenapitak, and S. Sangsuk, "Effects of WC addition on structure and hardness of electrodeposited Ni–W," Surface and Coatings Technology, vol. 203, no. 23, pp. 3590-3594, 2009. DOI: https://doi.org/10.1016/j.surfcoat.2009.05.027

S. Lee, M. Choi, S. Park, H. Jung, and B. Yoo, "Mechanical properties of electrodeposited Ni-W thinfilms with alternate W-rich and W-poor multilayers," Electrochimica Acta, vol. 153, pp. 225-231, 2015. DOI: https://doi.org/10.1016/j.electacta.2014.11.190

D. V. Suvorov, G. P. Gololobov, D. Y. Tarabrin, E. V. Slivkin, S. M. Karabanov, and A. Tolstoguzov, "Electrochemical deposition of Ni–W crack-free coatings," Coatings, vol. 8, no. 7, p. 8070233, 2018. DOI: https://doi.org/10.3390/coatings8070233

K. Ahmadi, S. Brankovic, M. Yarali, and O. Karadavut, Crack Formation during Electrodeposition and Post-deposition Aging of Thin Film Coatings. 2019.

R. Zhang, J. Liu, Z. Li, and G. Cui, "A novel superhydrophobic Ni-graphene coating and its corrosion resistance," Journal of Physics: Conference Series, vol. 2383, p. 012130, 2022. DOI: https://doi.org/10.1088/1742-6596/2383/1/012130

K. Kubiak, M. C. T. Wilson, T. Mathia, and P. Carval, "Wettability versus roughness of engineering surfaces," Wear, vol. 271, 2011. DOI: https://doi.org/10.1016/j.wear.2010.03.029

M. Razavifar, A. Abdi, E. Nikooee, O. Aghili, and M. Riazi, "Quantifying the impact of surface roughness on contact angle dynamics under varying conditions," Scientific Reports, vol. 15, no. 1, p. 16611, 2025. DOI: https://doi.org/10.1038/s41598-025-01127-7

B. Bhushan, and Y. C. Jung, "Natural and biomimetic artificial surfaces for superhydrophobicity, self-cleaning, low adhesion, and drag reduction," Progress in Materials Science, vol. 56, no. 1, pp. 1-108, 2011. DOI: https://doi.org/10.1016/j.pmatsci.2010.04.003

A. Milionis, E. Loth, and I. S. Bayer, "Recent advances in the mechanical durability of superhydrophobic materials," Advances in Colloid and Interface Science, vol. 229, pp. 57-79, 2016. DOI: https://doi.org/10.1016/j.cis.2015.12.007

T. L. Liu, and C.-J. C. Kim, "Turning a surface superrepellent even to completely wetting liquids," Science, vol. 346, no. 6213, pp. 1096-1100, 2014. DOI: https://doi.org/10.1126/science.1254787

N. Michael, and B. Bhushan, "Hierarchical roughness makes superhydrophobic states stable," Microelectronic Engineering, vol. 84, no. 3, pp. 382-386, 2007. DOI: https://doi.org/10.1016/j.mee.2006.10.054

X.-M. Li, D. Reinhoudt, and M. Crego-Calama, "What do we need for a superhydrophobic surface? A review on the recent progress in the preparation of superhydrophobic surfaces," Chemical Society Reviews, vol. 36, no. 8, pp. 1350-1368, 2007. DOI: https://doi.org/10.1039/b602486f

G. Vijaya, M. Singh, M. Krupashankara, and R. S. Kulkarni, "Effect of argon gas flow rate on the optical and mechanical properties of sputtered tungsten thin film coatings," IOP Conference Series: Materials Science and Engineering, vol. 149, p. 012075, 2016. DOI: https://doi.org/10.1088/1757-899X/149/1/012075

Y. Ma, J. Li, W. Liu, and Y. Shi, "A large-scale fabrication of flower-like submicrometer-sized tungsten whiskers via metal catalysis," Nanoscale research letters, vol. 7, p. 325, 2012. DOI: https://doi.org/10.1186/1556-276X-7-325

L. Elias, and A. Hegde, "Effect of graphene oxide on the electrocatalytic activity of Ni-W alloy coating," Insights in Analytical Electrochemistry, vol. 03, 2018. DOI: https://doi.org/10.21767/2470-9867.10002

L. Yu, J. Cao, and Y. Cheng, "An improvement of the wear and corrosion resistances of AZ31 magnesium alloy by plasma electrolytic oxidation in a silicate–hexametaphosphate electrolyte with the suspension of SiC nanoparticles," Surface and Coatings Technology, vol. 276, pp. 266-278, 2015. DOI: https://doi.org/10.1016/j.surfcoat.2015.07.014

C. A. Schuh, T. G. Nieh, and H. Iwasaki, "The effect of solid solution W additions on the mechanical properties of nano-crystalline Ni," Acta Materialia, vol. 51, no. 2, pp. 431-443, 2003. DOI: https://doi.org/10.1016/S1359-6454(02)00427-5

W. Pfeiffer, C. Koplin, E. Reisacher, and J. Wenzel, "Residual Stresses and strength of hard chromium coatings," Materials Science Forum, vol. 681, pp. 133-138, 2011. DOI: https://doi.org/10.4028/www.scientific.net/MSF.681.133

C. A. Schuh, T. G. Nieh, and T. Yamasaki, "Hall–Petch breakdown manifested in abrasive wear resistance of nanocrystalline nickel," Scripta Materialia, vol. 46, no. 10, pp. 735-740, 2002.. DOI: https://doi.org/10.1016/S1359-6462(02)00062-3

J. Sudagar, J. Lian, and W. Sha, "Electroless nickel, alloy, composite and nano coatings – A critical review," Journal of Alloys and Compounds, vol. 571, pp. 183-204, 2013. DOI: https://doi.org/10.1016/j.jallcom.2013.03.107

T. Ziebell, and C. Schuh, "Residual stress in electrodeposited nanocrystalline nickel-tungsten coatings," Journal of Materials Research, vol. 27, pp. 1271-1284, 2012. DOI: https://doi.org/10.1557/jmr.2012.51

P. Indyka, E. Beltowska-Lehman, L. Tarkowski, A. Bigos, and E. García-Lecina, "Structure characterization of nanocrystalline Ni–W alloys obtained by electrodeposition," Journal of Alloys and Compounds, vol. 590, pp. 75-79, 2014.. DOI: https://doi.org/10.1016/j.jallcom.2013.12.085

K. R. Sriraman, S. Ganesh Sundara Raman, and S. K. Seshadri, "Synthesis and evaluation of hardness and sliding wear resistance of electrodeposited nanocrystalline Ni–W alloys," Materials Science and Engineering: A, vol. 418, no. 1, pp. 303-311, 2006. DOI: https://doi.org/10.1016/j.msea.2005.11.046

S. Mbugua Nyambura, M. Kang, J. Zhu, Y. Liu, Y. Zhang, and N. J. Ndiithi, "Synthesis and characterization of Ni–W/ Cr2O3 nanocomposite coatings using electrochemical deposition technique," Coatings, vol. 9, no. 12, p. 815, 2019. DOI: https://doi.org/10.3390/coatings9120815

T. Wu, M. Ma, K. Ding, X. Nan, Z. Wang, X. Wei, and X. Zhu, "Effect of Y2O3 nanoparticles on the microstructure and corrosion resistance of electrodeposited Ni-Mo-Y2O3 nano-composite coatings," International Journal of Electrochemical Science, vol. 18, no. 6, p. 100095, 2023. DOI: https://doi.org/10.1016/j.ijoes.2023.100095

J. Deng, K. Li, J. Fu, B. Li, H. Jiang, H. Ju, E. Wang, C. Zhang, Y. Liu, Y. Chen, F. Wu, and C. Su, "Preparation and properties of textured Ni–W coatings electrodeposited on the steel surface from a pyrophosphate bath," Coatings, vol. 13, no. 9, p. 1519, 2023. DOI: https://doi.org/10.3390/coatings13091519

N. Sunwang, P. Wangyao, and Y. Boonyongmaneerat, "The effects of heat treatments on hardness and wear resistance in Ni–W alloy coatings," Surface & Coatings Technology, vol. 206, pp. 1096-1101, 2011. DOI: https://doi.org/10.1016/j.surfcoat.2011.07.082

S. Park, H. Han, J. Seo, J. Park, S. Yoon, and B. Yoo, "Electro-deposition of nickel-tungsten alloy with functional concentration periodically graded material structure for low stress and high hardness," Journal of The Electrochemical Society, vol. 171, 2024. DOI: https://doi.org/10.1149/1945-7111/ad2394

M. Dadvand, and O. Savadogo, "Effect of pulse reverse current waveform on tribological and mechanical properties of electro-deposited nickel–tungsten alloys on brass substrate," Tribology - Materials, Surfaces & Interfaces, vol. 16, no. 4, pp. 281-291, 2022. DOI: https://doi.org/10.1080/17515831.2022.2075649

K. Tønder, "Hydrodynamic effects of tailored inlet roughnesses: Extended theory," Tribology International, vol. 37, pp. 137-142, 2004. DOI: https://doi.org/10.1016/S0301-679X(03)00043-4

L. Wojciechowski, K. J. Kubiak, and T. G. Mathia, "Roughness and wettability of surfaces in boundary lubricated scuffing wear," Tribology International, vol. 93, pp. 593-601, 2016.. DOI: https://doi.org/10.1016/j.triboint.2015.04.013

C. Zhang, and M. Fujii, "Influence of wettability and mechanical properties on tribological performance of DLC coatings under water lubrication," Journal of Surface Engineered Materials and Advanced Technology, vol. 05, pp. 110-123, 2015. DOI: https://doi.org/10.4236/jsemat.2015.53013

I. Tudela, A. J. Cobley, and Y. Zhang, "Tribological performance of novel nickel-based composite coatings with lubricant particles," Friction, vol. 7, no. 2, pp. 169-180, 2019. DOI: https://doi.org/10.1007/s40544-018-0211-0

Q. Wang, and F. Zhou, "Progress in tribological properties of nano-composite hard coatings under water lubrication," Lubricants, vol. 5, no. 1, p. 5, 2017. DOI: https://doi.org/10.3390/lubricants5010005

C. Hu, L. Zhao, Y. Zhang, Z. Du, and Y. Deng, "The influence of hard coatings on fatigue properties of pure titanium by a novel testing method," Materials, vol. 17, no. 4, p. 835, 2024. DOI: https://doi.org/10.3390/ma17040835