Corrosion behavior of Ni–P/nano-TiC composite coating prepared in electroless baths containing different types of surfactant

In current research, in order to enhance the incorporation of nano-sized TiC particles into electroless Ni–P (EN) coating, different types of surfactant (cationic, anionic, and polymeric) were added to the plating bath. The effects of addition of the surfactants on surface morphology, deposition rate, TiC and P contents of the prepared coatings were investigated. The surface morphology was evaluated by scanning electron microscopy (SEM). It was demonstrated that in the presence of the anionic, polymeric and somehow cationic surfactants, TiC nano-particles were embedded in the matrix which influenced the surface morphology. The effect of surfactant types on the corrosion properties of Ni–P/TiC coated steel was also studied. Corrosion behavior of the coated steel was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) which affected by the incorporation of TiC particles into the Ni–P matrix. The level of corrosion resistance improvement depended largely on the phosphorous and TiC concentration of the applied coating.     

Microstructure of Ni–Al powder and Ni–Al composite coatings prepared by twin-wire arc spraying

Ni–Al powder and Ni–Al composite coatings were fabricated by twin-wire arc spraying (TWAS). The microstructures of Ni-5wt%Al powder and Ni-20wt%Al powder were characterized by scanning electronic microscopy (SEM) and energy dispersive spectroscopy (EDS). The results showed that the obtained particle size ranged from 5 to 50 μm. The morphology of the Ni–Al powder showed that molten particles were composed of Ni solid solution, NiAl, Ni₃Al, Al₂O₃, and NiO. The Ni–Al phase and a small amount of Al₂O₃ particles changed the composition of the coating. The microstructures of the twin-wire-arc-sprayed Ni–Al composite coatings were characterized by SEM, EDS, X-ray diffraction (XRD), and transmission electron microscopy (TEM). The results showed that the main phase of the Ni-5wt%Al coating consisted of Ni solid solution and NiAl in addition to a small amount of Al₂O₃. The main phase of the Ni-20wt%Al coating mainly consisted of Ni solid solution, NiAl, and Ni₃Al in addition to a small amount of Al and Al₂O₃, and NiAl and Ni₃Al intermetallic compounds effectively further improved the final wear property of the coatings. TEM analysis indicated that fine spherical NiAl₃ precipitates and a Ni–Al–O amorphous phase formed in the matrix of the Ni solid solution in the original state.     

Reusing oxide-based pulverised fly ash and medical waste particles to develop electroless nickel composite coatings(Ni–P/fly ash and Ni–P/SiO_2–Al_2O_3)

Recycling and reusing materials from waste have become a nexus in the development of sustainable materials, leading to more balanced technologies. In this study, we developed a composite coating by co-depositing recycled ceramic particles, pulverised fly ash(PFA) and medical ceramics(MC), into a nickel–phosphorus matrix using a typical electroless plating process. Scanning electron microscopy(SEM) images indicated well-dispersed particles in the Ni–P matrix. However, compared with the MC particles, the PFA particles were distributed scantily with a lower content in the matrix, which could be due to the less impingement effect during the co-deposition. A modified microstructure with refined grains was obtained for the PFA-incorporated composite coating, as seen in the SEM micrograph. The X-ray diffraction result of the MC-incorporated composite coating showed the formation of Nix Siy phases in addition to the typical Ni3 P phases for the heattreated electroless Ni–P coatings. Upon heat treatment, the PFA-reinforced composite coating, due to a modified microstructure, exhibited a higher microhardness up to HK0.05 818, which is comparable to that of the traditional SiC particle-embedded composite coating(HK0.05 825).The findings can potentially open up a new strategy to further advance the green approach for industrial surface engineering.     

Effect of pickling processes on the microstructure and properties of electroless Ni–P coating on Mg–7.5Li–2Zn–1Y alloy

The electroless plating Ni–P is prepared on the surface of Mg–7.5Li–2Zn–1Y alloys with different pickling processes.The microstructure and properties of Ni–P coating are investigated.The results show that the Ni–P coatings deposited using the different pickling processes have a different high phosphorus content amorphous Ni–P solid solution structure,and the Ni–P coatings exhibit higher hardness.There is higher phosphorus content of Ni–P amorphous coating using 125 g/L Cr O3and 110 ml/L HNO3(w68%)than using 180 g/L Cr O3and 1 g/L KF during pre-treatment,and the coating structure is more compact,and the Ni–P coatings exhibit more excellent adhesion with substrate(Fcup to22 N).The corrosion potential of Ni–P coating is improved and exhibits good corrosion resistance.As a result,Mg-7.5Li-2Zn-1Y alloy is remarkably protected by the Ni–P coating.     

Solid particle erosion studies of thermally deposited alumina–titania coatings on an aluminum alloy

Thermal barrier coatings are widely used as surface modifications to enhance the surface properties of the material and protect from surface degradations such as erosion and corrosion. Ceramic-based coatings are highly recommended to increase wear resistance in the industrial sector. In this paper, an alumina–titania ceramic powder was deposited on an aluminum alloy using an atmospheric plasma spray technique. Experimental investigations were performed to study the behavior and erosion rate of the material. Solid particle erosion studies were performed by varying the particle velocity and particle flow rate. The angle impingement and stand-off distance were constant for comparison.The base metal has a clinging effect and the mass change was negative at a maximum particle flow rate of 4 g·min~(-1). Under the same process conditions, the coated sample had a reduced lifetime and reached a maximum erosion rate of 0.052(Δg/g). The solid particle erosion studies confirmed that the base metal aluminum alloy had severe surface damage with erodent reinforcement when compared to the coated samples.The influence of the particle velocity, particle flow rate, and input process parameters were also identified.     

Preparation of in situ and ex situ reinforced Fe–10Cr–1Cu–1Ni–1Mo–2C containing NbC particles by milling and hot pressing

An in situ and ex situ reinforced powder metallurgy(PM) steel was prepared by the combination of high-energy ball milling and subsequent hot pressing of elemental mixed powders of Fe–10Cr–1Cu–1Ni–1Mo–2C by mass with the addition of Nb C particles. A 40-h milling pretreatment makes the powder particles nearly equiaxed with an average diameter of ~8 μm, and the ferrite grain size is refined to ~6 nm. The sintered density reaches 99.0%–99.7% of the theoretical value when the sintering is conducted at temperatures greater than 1000°C for 30 min. In the sintered bulk specimens, the formation of an in situ M7C3(M = Cr, Fe, Mo) phase is confirmed. M7C3 carbides with several hundred nanometers in size are uniformly distributed in the matrix. Some ultra-fine second phases of 50–200 nm form around the ex situ Nb C and in situ M7C3 particles. The sintered steel exhibits an excellent combination of hardness( Hv 500) and compressive strength(2100–2420 MPa).     

In situ synthesis of Fe-based alloy clad coatings containing TiB_2–TiN –(h-BN)

Fe-based alloy coatings containing TiB2–TiN –(h-BN) were synthesized in situ on Q235 steel substrates by a plasma cladding process using the powders of Fe901 alloy, Ti, and h-BN as raw materials. The effects of Ti/h-BN mass ratio on interfacial bonds between the coating and substrate along with the microstructures and microhardnesses of the coatings were investigated. The results show that the Ti/h-BN mass ratio is a vital factor in the formation of the coatings. Free h-BN can be introduced into the coatings by adding an excess amount of h-BN into the precursor. Decreases in the Ti/h-BN mass ratio improve the microstructural uniformity and compactness and enhance the interfacial bonds of the coatings. At a Ti/h-BN mass ratio of 10/20, the coating is free of cracks and micropores, and mainly consists of Fe-Cr, Fe3B, TiB2, TiN, Ti2N, TiB, FeN, FeB, Fe2B, and h-BN phases. Its average microhardness in the zone between 0.1–2.8 mm from the coating surface is about Hv0.2 551.5.     

Fabrication of Ni–Mo–Nb metallic glass/micro-nano lattice composite for nonenzymatic glucose sensing

The rising global diabetic population has ignited significant interest in enzyme-free electrochemical glucose sensors.However,their widespread usage has been severely impeded by the lack of sensing probes with both high sensitivity and stability.In this work,we present a novel approach for conformally depositing a Ni-Mo-Nb metallic-glass film onto a three-dimensional printed polymer skeleton for glucose detection.The printing template is designed based on a six-membered tricapped trigonal prism(...     

Kinetics of discontinuous precipitation in Cu–20Ni–20Mn alloy

The morphology and growth kinetics of discontinuous precipitation (DP) in a Cu–20Ni–20Mn alloy were investigated in the temperature range of 523–673 K by optical microscopy, scanning electron microscopy, and transmission electron microscopy. A lamellar mixed structure consisting of alternating lamellae of a matrix and NiMn phase was observed in DP colonies. The volume fraction of regions formed by a DP reaction was determined by quantitative metallographic measurements. The kinetics of DP was evaluated on the basis of the Johnson–Mehl–Avrami–Kolmogorov equation, which resulted in a time exponent of approximately 1.5. We confirmed that the nucleation of the discontinuous precipitate was confined to grain edges or boundaries at an early stage of the reaction. The activation energy of DP process was determined to be approximately (72.7 ±7.2) kJ/mol based on the Arrhenius equation; this result suggests that DP is controlled by grain boundary diffusion. The hardness values exhibited good correlation with the volume fraction of DP; this correlation was attributed to the presence of the ordered NiMn phase.     

Preparation of Al2O3–SiO2 composite aerogels and their Cu2+absorption properties

In order to remediate heavy metal ions from waste water,Al2O3–SiO2 composite aerogels are prepared via a sol–gel and an organic solvent sublimation drying method.Various characterisation techniques have been employed including X-ray diffraction(XRD),Fourier transform infrared spectrometry(FTIR),scanning electron microscope(SEM),Energy-dispersion X-ray spectroscopy(EDX),Brunauer–Emmett–Teller(BET)N2 adsoprtion isotherm,and atomic absorption spectrometer(AAS).XRD and FTIR suggest that the aerogels are composed of mainly Al2O3 and minor SiO2.They have a high specific surface area(827.544 m^2/g)and high porosity(86.0%)with a pore diameter of~20 nm.Their microstructures show that the distribution of Al,Si,and O is homogeneous.The aerogels can remove~99%Cu^2+within~40 min and then reach the equilibrium uptake(~69 mg/g).Preliminary calculations show that the Cu2+uptake by the aerogels follows pseudo second-order kinetics where chemical sorption may take effect owing largely to the high surface area,high porosity,and abundant functional groups,such as Al–OH and Si–OH,in the aerogel network.The prepared aerogels may serve as efficient absorbents for Cu^2+removal.     

Electroplating of Ni/Co–pumice multilayer nanocomposite coatings: Effect of current density on crystal texture transformations and corrosion behavior

The present paper aims to investigate the influence of the current density in the electroplating process on the microstructure, crystal texture transformations, and corrosion behavior of Ni/Co-pumice multilayer nanocomposite coatings. The Ni/Co-pumice composite coatings were prepared by deposition of Ni, followed by the simultaneous deposition of pumice nanoparticles (NPs) in a Co matrix via an electroplating process at various current densities. Afterward, the morphology, size, topography, and crystal texture of the obtained samples were investigated. Furthermore, electrochemical methods were used to investigate the corrosion behavior of the produced coatings in a solution of 3.5wt% NaCl. The results indicated that increasing the plating current density changed the mechanism of coating growth from the cell state to the column state, increased the coating thickness, roughness, and texture coefficient (TC) of the Co (203) plane, and reduced the amount of pumice NPs incorporated into the Ni/Co-pumice composite. The electrochemical results also indicated that increasing the current density enhanced the corrosion resistance of the Ni/Co-pumice composite.     

Microstructural analysis and hot corrosion behavior of HVOF-sprayed Ni–22Cr–10Al–1Y and Ni–22Cr–10Al–1Y–SiC(N) coatings on ASTM-SA213-T22 steel

The present paper deals with the investigation of microstructure and high-temperature hot corrosion behavior of high-velocity oxy fuel(HVOF)-produced coatings. Two powder coating compositions, namely, Ni22Cr10Al1Y alloy powder and Ni22Cr10Al1Y(80 wt%; microsized)–silicon carbide(SiC)(20 wt%; nano(N)) powder, were deposited on a T-22 boiler tube steel. The hot corrosion behavior of bare and coated steels was tested at 900°C for 50 cycles in Na_2SO_4–60 wt%V_2O_5 molten-salt environment. The kinetics of corrosion was established with weight change measurements after each cycle. The microporosity and microhardness of the as-coated samples have been reported. The X-ray diffraction,field emission-scanning electron microscopy/energy dispersive spectroscopy, and X-ray mapping characterization techniques have been utilized for structural analysis of the as-coated and hot-corroded samples. The results showed that both coatings were deposited with a porosity less than2%. Both coated samples revealed the development of harder surfaces than the substrate. During hot corrosion testing, the bare T22 steel showed an accelerated corrosion in comparison with its coated counterparts. The HVOF-sprayed coatings were befitted effectively by maintaining their adherence during testing. The Ni22Cr10Al1Y–20 wt%SiC(N) composite coating was more effective than the Ni–22Cr–10Al–1Y coating against corrosion in the high-temperature fluxing process.     

Facile synthesis of composite polyferric magnesium–silicate–sulfate coagulant with enhanced performance in water and wastewater

The coagulation process is a widely applied technology in water and wastewater treatment. Novel composite polyferric magnesium–silicate–sulfate(PFMS) coagulants were synthesized using Na₂SiO₃·9H₂O, Fe₂(SO₄)₃, and MgSO₄ as raw materials in this paper.The effects of aging time, Fe:Si:Mg, and OH:M molar ratios(Mrepresents the metalions) on the coagulation performance of the as-prepared PFMS were systematically investigated...     

Synergetic effect of multiple phases on hydrogen desorption kinetics and cycle durability in ball milled MgH2–PrF3–Al–Ni composite

A new Mg MgH₂–PrF₃–Al–Ni composite was prepared by ball milling under hydrogen atmosphere. After initial dehydrogenation and rehydrogenation, Pr₃Al₁₁, MgF₂, PrH₃ and Mg₂NiH₄ nanoparticles formed accompanying the main phase MgH₂. The hydrogen absorption-desorption properties were measured by using a Sieverts-type apparatus. The results showed that the Mg MgH₂–PrF₃–Al–Ni composi...     

Preparation and characterizat ion of polypropylene/silica composite particl e with interpenetrating network via hot emulsion sol–gel approach

A novel interpenetrating structural ultrafine polypropylene-silica nanocomposite particles were synthesized by a modified sol–gel approach in the presence of the melt polypropylene emulsion. A series of samples with different polypropylene content was prepared to investigate the unique characteristics of this original nanocomposite. The thermal gravimetric analysis and differential scanning calorimetry results showed that the nanocomposites had the interpenetrating structure and good thermal stability,and the crystallization behavior of polypropylene was confined by the silica matrix. The interpenetrating structure of nanocomposites was also suggested by the nitrogen adsorption–desorption measurement results. The scanning electronic microscope and transmission electron microscopy images indicated that the nanocomposites had irregular particle morphology. The nanoparticle tracking analysis results show that the mean size of the nanocomposites was around 160 nm. According to the results obtained from different measurements,a reasonable formation mechanism was proposed.     

Growth in solution of hooked Ni–Fe fibers by oriented rotation and attachment approaches

Inspired by the curved branches of fractal trees, hooked Ni–Fe fibers were grown in situ in Ni–Fe composite coatings on a spheroidal graphite cast iron substrate. These hooked Ni–Fe fibers exhibited inclination angles of about 39°, which was in accordance with the theoretical prediction of 37°. Ni–Fe nanostructures self-assembled to form dendrites and evolved into hooked fibers by an oriented attachment reaction. The orientation rotation of Ni–Fe nanostructures played an important role in the growth of curved hooked Ni–Fe fibers. During sliding wear tests, the volume loss of the spheroidal graphite cast iron substrate was 2.2 times as large as that of the Ni–Fe coating reinforced by hooked fibers. The good load-transferring ability of hooked Ni–Fe fibers led to an improvement in their wear properties during wear tests.     

Electrochemical behavior and corrosion resistance of IrO_2–ZrO_2 binary oxide coatings for promoting oxygen evolution in sulfuric acid solution

In this study, we prepared Ti/IrO_2–ZrO_2 electrodes with different ZrO_2 contents using zirconium-n-butoxide(C_(16)H_(36)O_4Zr) and chloroiridic acid(H_2IrCl_6) via a sol–gel route. To explore the effect of ZrO_2 content on the surface properties and electrochemical behavior of electrodes, we performed physical characterizations and electrochemical measurements. The obtained results revealed that the binary oxide coating was composed of rutile IrO_2, amorphous ZrO2, and an IrO_2–ZrO_2 solid solution. The IrO_2–ZrO_2 binary oxide coatings exhibited cracked structures with flat regions. A slight incorporation of ZrO_2 promoted the crystallization of the active component IrO_2. However, the crystallization of IrO_2 was hindered when the added ZrO_2 content was greater than 30 at%. The appropriate incorporation of ZrO_2 enhanced the electrocatalytic performance of the pure IrO_2 coating. The Ti/70 at%IrO_2–30 at%ZrO_2 electrode, with its large active surface area, improved electrocatalytic activity, long service lifetime, and especially, lower cost, is the most effective for promoting oxygen evolution in sulfuric acid solution.     

Activity coefficients of NiO and CoO in CaO–Al_2O_3–SiO_2 slag and their application to the recycling of Ni–Co–Fe-based end-of-life superalloys via remelting

To design optimal pyrometallurgical processes for nickel and cobalt recycling, and more particularly for the end-of-life process of Ni–Co–Fe-based end-of-life(EoL) superalloys, knowledge of their activity coefficients in slags is essential. In this study, the activity coefficients of NiO and CoO in CaO–Al_2O_3–SiO_2 slag, a candidate slag used for the EoL superalloy remelting process, were measured using gas/slag/metal equilibrium experiments. These activity coefficients were then used to consider the recycling efficiency of nickel and cobalt by remelting EoL superalloys using CaO–Al_2O_3–SiO_2 slag. The activity coefficients of NiO and CoO in CaO–Al_2O_3–SiO_2 slag both show a positive deviation from Raoult's law, with values that vary from 1 to 5 depending on the change in basicity. The activity coefficients of NiO and CoO peak in the slag with a composition near B =(%CaO)/(%SiO_2) = 1, where B is the basicity. We observed that controlling the slag composition at approximately B = 1 effectively reduces the cobalt and nickel oxidation losses and promotes the oxidation removal of iron during the remelting process of EoL superalloys.     

Effects of Cr and Mo elements on the microstructures and compressive properties of the in situ (TiC_xN_y–TiB_2)/Ni cermets

In-situ(TiC_xN_y–TiB_2)/Ni cermets with 70 wt%TiC_xN_y–TiB_2 were successfully fabricated by combustion synthesis and hot pressing sintering in Ni-Ti-B_4C-BN powder systems.The microstructures,density,compressive properties,and hardness of the TiC_xN_y–TiB_2/Ni cermets with the addition of 0–8 wt%Cr/Mo to the Ni-Ti-B_4C-BN powder systems were compared and analysed.The results showed that the ceramic particles distributed uniformly in the cermets,and the size of the ceramic particles reduced with the Cr/Mo addition.Both Cr and Mo addition can improve the hardness,compressive properties,and fracture strains of the cermets.The hardness,compressive strength,and fracture strain of the(TiC_xN_y–TiB_2)/(Ni+Cr)cermets increased from 1561 HV,2.94 GPa,and 2.9%to 1864 HV,3.65 GPa,and 3.4%,respectively when the Cr content increased to 5 wt%.The hardness and compressive strength of the(TiC_xN_y–TiB_2)/(Ni+Mo)cermets increased from 1561 HV and 2.94 GPa to 1902 HV and 3.43 GPa,respectively when the Mo content increased to 8 wt%.The cermets with Cr had better compressive properties than the cermets with Mo.     

The precipitation strengthening behavior of Cu-rich phase in Nb contained advanced Fe–Cr–Ni type austenitic heat resistant steel for USC power plant application

Copper has been used as a strengthening element in newly developed Fe–Cr–Ni type austenitic heat resistant steel for inducing Cu-rich phase precipitation to meet high temperature strength requirement for 60°C Ultra Super-Critical (USC) coal fired power plants for many years. However, the precipitation behavior and strengthening mechanism of Cu-rich phase in these advanced austenitic heat resistant steels is still unclear. In order to understand the precipitation strengthening behavior of Cu-rich phase and to promote high strength austenitic heat resistant steel development, 18Cr9 NiCuNb steel which is a Cu-added Nb contained advanced Fe–Cr–Ni type austenitic heat resistant steel has been selected for this study to be aged at 650°C till to 10,000 h. Micro-hardness and room temperature tensile test were conducted after long-time aging. SEM,TEM, HRTEM and three dimensional atom probe (3DAP) technology accompanying with thermodynamic calculation have been used to investigate the Cu-rich phase precipitation behavior during 650°C aging. The experimental results showed that Cu atoms can quickly concentrate in clusters at very early precipitation stage to form the fine nano-size Cu-rich ‘‘segregation areas’within less than 1 h at 650°C. With increasing aging time at 650°C Cu atoms continuously concentrate to Cu-rich segregation areas (clusters) and simultaneously other kinds of atoms such as Fe, Cr and Ni diffuse away from Cu-rich segregation areas to austenitic matrix, and finally to complete the transformation from Cu-rich segregation areas to Cu-rich phase. However, there is only Cu atoms concentration but not crystallographic transformation from early stage of Cu-rich clusters forming to the final Cu-rich phase formation. Even the Cu atom becomes the main composed element after 500 h aging at 650°C the Cu-rich phase still keeps coherent relationship with austenitic matrix. According the experimental results in this study, Cu-rich phase precipitation sequence which starts from the Cu atom segregation followed by the Cu diffusing from matrix to segregation areas and Fe, Cr and Ni atoms diffuse out from Cu-rich areas to matrix without crystallographic transformation is proposed. The Cu-rich phase is the most dispersed phase and contributes the most important strengthening effect among all precipitated phases (M23C6, MX and Cu-rich phase). It has been found that Cu-rich phase is very stable and still keeps in nano-size even for 10,000 h aging at 650°C. The unique precipitation strengthening of Cu-rich phase in combination with nano-size Nb-rich MX phase and grain-boundary M23C6carbide contributes excellent strengthening effect to 18Cr9 NiCuNb austenitic heat resistant steel.