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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

Journal of Ceramic Science and Technology, Vol. 17, No. 1 (2026), pp. 71-82

DOI: 10.4416/JCST2025-00020

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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.

Keywords

Microstructural refinement, corrosion resistance, mechanical integrity, wear resistance, tribological properties.

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