Synergy between Wear and Corrosion in Electrodeposited Ni-W and Hard Chrome Coatings

Tribocorrosion is a common issue for hydraulic actuators operating in wet and marine environments. Electrolytic hard chrome (HCr) coatings are used to protect these actuators from tribocorrosion. Due to environmental concerns, electrodeposited Ni-W alloy coatings are considered as a suitable alternative for chrome plating because of their superior hardness and corrosion resistance. Under tribocorrosion conditions, the application of Ni-W coatings requires thorough investigation. In this study, the comparative tribocorrosion of Ni-W and HCr coatings was examined according to ASTM G119-09 in 3.5 wt% NaCl at a 10 N load. Ni-W coatings showed consistently lower friction coefficients compared to HCr, regardless of the applied potential. At open circuit potential (OCP), Ni-W coatings exhibited stable OCP with wear volume approximately 52% lower than HCr coatings. The wear corrosion synergy factor for HCr coatings was 1.5 times higher than Ni-W, indicating that the combined effects of wear and corrosion was more detrimental to HCr coatings. The presence of self-repairing, lubricious WO 3 and NiWO 4 oxides on the worn surface of Ni-W was confirmed through Raman spectroscopy. The findings were explained using mixed potential theory, oxide film composition analysis, and evaluation of wear-induced subsurface stresses through contact mechanics.

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