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Electrochemical Deposition of Ni-Zn Oxide Coatings on Roll Knife Surfaces: Process Parameters and Performance Effects
Quangang Li, Jianbo Zhou, Xiaohong Wang
Harbin Research Institute of Forestry Machinery, National Forestry and Grassland Administration, Harbin 150086, Heilongjiang, China
received June 30, 2025, received in revised form August 4, 2025, accepted September 5, 2025
Vol. 17, No. 1, Pages 71-82 DOI: 10.4416/JCST2025-00020
Abstract
An innovative electrodeposition method was developed to fabricate Ni-ZnO composite coatings on high-carbon stainless steel substrates for industrial cutting applications. In this study, key deposition parameters including current density (ranging from 2 to 8 A/dm2), bath pH (optimally maintained at 10), temperature (45 °C), and stirring rate (250 rpm) were systematically optimized to enhance coating properties. The integration of ZnO nanoparticles resulted in a refined microstructure, reducing the average grain size from 0.72 µm to 0.56 µm, while the coating thickness increased from 11.1 µm at lower current levels to 24.1 µm at 8 A/dm2. Under optimal conditions at 6 A/dm², the deposition efficiency reached approximately 85 %. Electrochemical evaluations demonstrated a substantial improvement in corrosion resistance; charge transfer resistance increased from 452 Ω·cm2 for uncoated substrates to 2 370 Ω·cm2 for pure nickel coatings and further to 5 515 Ω·cm2 for the composite, while corrosion current density was reduced from 30 µA/cm² to 7.9 µA/cm2. Mechanical testing revealed that the composite coating exhibited a hardness of 4.8 GPa and a Young's modulus of 88 GPa, in contrast to 2.9 GPa and 52 GPa for pure nickel layers. Additionally, abrasion tests indicated a decrease in weight loss from 66 mg to 27 mg over a 35 km sliding distance. Overall, the findings confirm that the strategic incorporation of ZnO nanoparticles significantly enhances both the structural integrity and protective capability of the coating, offering a robust and cost-effective solution for prolonging the service life of industrial components. These promising results pave the way forward.
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Keywords
Microstructural refinement, corrosion resistance, mechanical integrity, wear resistance, tribological properties.
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