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Development of Wear and Corrosion Resistant Nickel Based Coatings Through Pulse Reverse Current (PRC) Electrodeposition Process

Shreeram, Devesh Dadhich
http://rave.ohiolink.edu/etdc/view?acc_num=akron1509839587682532

Abstract Details

2017, Doctor of Philosophy, University of Akron, Chemical Engineering.
Corrosion is estimated to have cost the global economy over $2.2 trillion in 2010 (~3.5% global GDP); corrosion-resistant coatings are a multibillion-dollar market. None of the current industrial corrosion-resistant coatings provide significant wear resistance for mechanical applications such as, bearing and powertrains. Development of a single coating with high corrosion and wear resistance can fulfill this unmet need. Research in this project tests two primary hypotheses: (1) is it possible to use pulsed reverse current (PRC) electrodeposition processes to develop coatings with corrosion and a tribological performance comparable to industrial baseline standards? ; and (2) is it possible to use the PRC process to develop coatings that promote synergistic benefits with typical extreme pressure and anti-wear lubricant additives that should provide enhanced durability and friction-reduction to oil-lubricated mechanical systems?. Electrodeposited coatings were developed and analyzed using, Scanning Electron Microscope (SEM), Energy Dispersive Spectroscopy (EDS), X-ray Diffraction (XRD), Transmission Electron Microscopy (TEM), X-ray Photoelectron Spectroscopy (XPS), Auger Electron Spectroscopy (AES), High Frequency Reciprocating Rig (HFRR), Pin on Disk (POD) and 3D Optical Profilometer. The corrosion and tribological performance of developed coatings was compared to the performance of baseline industrial materials such as, uncoated AISI 52100, Tungsten Carbide (WC) doped diamond like carbon (DLC) coatings, ZnNi and chromate coatings. Two types of Ni-W coatings i.e. millisecond and second range were developed via pulse reverse current (PRC) electrodeposition process. Effect of doping TiO2 nanoparticles in the millisecond range Ni-W matrix was also observed. Ni-P coatings were developed using fixed millisecond and second range parameter settings. Results showed that the second and millisecond range deposition processes had distinct effects on the properties of the coatings. Developed Ni-W and Ni-P coatings had corrosion resistance similar to the ZnNi coating and better than the 52100 and WC/DLC. The second range Ni-W coatings in fully-formulated engine oil had lowest friction coefficient values and no measurable wear. It was also observed that the tribofilm structure and stability on the second range Ni-W surfaces were peculiar when compared to all other coatings. The observed data supports both hypothesis 1 and 2.
Gary L. Doll (Advisor)
Paul J. Shiller (Committee Member)
Hongbo Cong (Committee Member)
Rajeev K. Gupta (Committee Member)
Gregory N. Morscher (Committee Member)
Richard L. Einsporn (Committee Member)
266 p.
Chemical Engineering; Materials Science
Coatings, Electrodeposition, Ni-alloys, Corrosion, Wear, Tribology

Recommended Citations

Citations

  • Shreeram, D. D. (2017). Development of Wear and Corrosion Resistant Nickel Based Coatings Through Pulse Reverse Current (PRC) Electrodeposition Process [Doctoral dissertation, University of Akron]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=akron1509839587682532

    APA Style (7th edition)

  • Shreeram, Devesh Dadhich. Development of Wear and Corrosion Resistant Nickel Based Coatings Through Pulse Reverse Current (PRC) Electrodeposition Process. 2017. University of Akron, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=akron1509839587682532.

    MLA Style (8th edition)

  • Shreeram, Devesh Dadhich. "Development of Wear and Corrosion Resistant Nickel Based Coatings Through Pulse Reverse Current (PRC) Electrodeposition Process." Doctoral dissertation, University of Akron, 2017. http://rave.ohiolink.edu/etdc/view?acc_num=akron1509839587682532

    Chicago Manual of Style (17th edition)

akron1509839587682532
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© 2017, all rights reserved.
This open access ETD is published by University of Akron and OhioLINK.