Wear and Corrosion Performance of Nickel Phosphorous/Nickel Boron Nano Composite Duplex Coating

The development of multifunctional coatings with enhanced wear and corrosion resistance remains a significant challenge in surface engineering, particularly for applications demanding durability in aggressive environments. In this context, the present study investigates the effect of graphene nanoparticle incorporation on the structural and electrochemical behaviour of electroless deposited NiP/NiB duplex Coating. A Key challenge in such a system lies in achieving uniform dispersion of nanoparticles without agglomeration, which often impairs performance. X-ray diffraction analysis confirmed the formation of crystalline phases of Nickel boride and nickel phosphide in both pristine and graphene-reinforced coatings. Notably, the introduction of 0.25   wt% graphene induced a structural shift, evidenced by the emergence of a distinct peak at 2θ = 26.6°, indicating successful graphene integration. wear testing demonstrated a significant improvement at 0.75   wt% grapene, reducing the wear rate from 0.33   mm³/N·m (pristine) to 0.19   mm³/N·m. In contrast, corrosion resistance peaked at 0.25   wt% graphene, reducing the corrosion rate from 7.17×10 -3 mils/year (pristine) to 5.6 ×10 -3 mils/year. These findings underscore like critical role of graphene concentration in tailoring Coating performance and highlight the necessity of compositional optimization to fully exploit the synergistic effects of nanoparticle reinforcement without triggering adverse agglomeration effects.

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