Optimization of Plating Process on Inner Wall of Metal Pipe and Research on Coating Performance
Abstract
:1. Introduction
2. Materials and Methods
2.1. Experimental Device and Process Flow
2.2. Bath Composition and Process Conditions
2.3. Experimental Design
2.4. Test Instruments
- (1)
- The surface morphology of the coating was analyzed using a Quanta 200 scanning electron microscope (Quanta 200, FEI Company, Hillsboro, OR, USA) at a magnification of 2000 times.
- (2)
- The hardness of the deposited layer was characterized using a microhardness tester (VMH-002V, UHL, Asslar, Germany). A load of 25 gf was applied at 5 different positions for 15 s, and the average value of the obtained data were recorded.
- (3)
- The cross-section of the coating was observed using a Leica DMi8 M metallographic microscope at a magnification of 500 times (Leica DMi8 M, Leica, Wetzlar, Germany).
- (4)
- Electrochemical experiments were performed using an electrochemical workstation (CS2350, Wuhan Keist Instrument Co., Ltd., Wuhan, China) in a 3.5 wt% NaCl corrosion medium at room temperature. The three-electrode system had a saturated calomel electrode (SCE) as the reference electrode, a platinum electrode as the working electrode, and a potential range of 1500 mV to 1000 mV with a scan rate of 1 mV/s.
- (5)
- The deformation resistance of the coating was analyzed using a G200 nanoindenter (KLA, Hayward, CA, USA). A load of 100 mN was applied to 5 different points on the surface of the coating, with a Poisson’s ratio of 0.25 set based on the material properties.
3. Results and Discussion
3.1. Process Optimization
3.1.1. Optimization of Pretreatment Process and Bath Configuration
3.1.2. Trial Production of Pipe Inner Wall Coating after Process Optimization
3.2. Surface Morphology of Pipe Inner Wall Coating under Different Voltage
3.3. Cross-Sectional Morphology and Deposition Rate Analysis
3.4. Hardness of Pipe Inner Wall Coating under Different Voltage
3.5. Corrosion Resistance of Pipe Inner Wall Coating under Different Voltage
3.6. Elastic-Plastic Deformation Capacity of Pipe Inner Wall Coating under Different Voltage
4. Conclusions
- (1)
- Through the optimization of the pre-treatment process and plating solution formula, nine steps in the electro-brush plating process have been simplified to five steps. Moreover, Ni coatings with dense and uniform surface and good performance can be prepared conveniently and efficiently on the inner wall of metal pipes.
- (2)
- As the working voltage gradually increases, the surface and cross-sectional morphology of the pipe inner wall coating exhibit a trend of improvement followed by deterioration. The deposition rate shows a trend of acceleration followed by deceleration. By using an appropriate working voltage (12 V), a coating with superior surface and cross-sectional morphology, as well as good adhesion to the substrate, can be obtained while maintaining a high deposition rate (169.2 μm/h).
- (3)
- The microhardness, corrosion resistance, and elastic-plasticity of the Ni coating prepared on the inner wall of the pipe show a trend of initially increasing and then decreasing as the working voltage gradually increases. The coating exhibits the best surface quality, the fewest defects, and the most significant grain refinement effect when the working voltage is 12V. At this voltage, the coating has a hardness of 575.8 HV, a corrosion current density of 1.040 × 10−5 A·cm−2, a corrosion rate of 0.122 mm·a−1, and an elastic recovery ratio (he/hmax) of 0.36. The results indicate that the coating prepared at 12 V has the best microhardness, corrosion resistance, and deformation resistance.
- (4)
- Ni coating on the inner wall of a metal pipe via an optimized electro-brush plating deposition process. Compared with the coating on the inner wall of commercially available galvanized steel pipes, the resultant Ni coating exhibited significant enhancements in surface morphology, coating hardness, corrosion resistance, and elastoplasticity. Moreover, the proposed method features several advantages including simple and convenient equipment, uniform and dense surface morphology, high deposition rate, and simplified plating solution and process.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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Bath Compositions | Concentration | Depositing Parameters | Values |
---|---|---|---|
NiSO4·6H2O | 250 (g·L−1) | Temperature | 25 (°C) |
C2H7NO2 | 45 (g·L−1) | pH | 6.5–7.5 |
(NH4)3C6H5O7 | 35 (g·L−1) | Brush head speed | 10 (m/min) |
C2H8N2O4·H2O | 1 (g·L−1) | Time | 5 (min) |
NH3·H2O | 100 (mL/L) | working voltage | 8 V |
Bath supply speed | 16 (mL/min) |
Bath Compositions | Concentration | Depositing Parameters | Values |
---|---|---|---|
NiSO4·6H2O | 250 (g·L−1) | Temperature | 25 (°C) |
C2H7NO2 | 45 (g·L−1) | pH | 6.5–7.5 |
(NH4)3C6H5O7 | 35 (g·L−1) | Brush head speed | 100,180,260 (r/min) |
C2H8N2O4·H2O | 1 (g·L−1) | Time | 5 (min) |
NH3·H2O | 100(mL/L) | working voltage | 6 V, 8 V, 10 V, 12 V, 14 V, 16 V |
Surfactant | 0.1 (g·L−1) | Bath supply speed | 16 (mL/min) |
First Pre-Treatment | Second Pre-Treatment | Third Pre-Treatment | |
---|---|---|---|
Step | Operation | Operation | Operation |
1 | Electroclean | Lye degreasing | Lye degreasing |
2 | Rinse | Rinse | Rinse |
3 | Activate 1 | Mixed acid activation (15%HNO3 + 15% H3PO4) | Impurity removal and activate (5%HCl) |
4 | Rinse | Rinse | Rinse |
5 | Activate 2 | Pure Ni plating | Pure Ni plating |
6 | Rinse | ||
7 | Pre-nickel plating | ||
8 | Rinse | ||
9 | Pure Ni plating |
Number | Corrosion Potential/V | Corrosion Current Density/A·cm−2 | Corrosion Rate/mm·a−1 |
---|---|---|---|
P | –1.281 | 7.651 × 10−5 | 0.898 |
P-1 | –0.727 | 3.615 × 10−5 | 0.424 |
P-2 | –0.735 | 1.749 × 10−5 | 0.205 |
P-3 | –0.721 | 1.262 × 10−5 | 0.148 |
P-4 | –0.695 | 1.040 × 10−5 | 0.122 |
P-5 | –0.735 | 2.589 × 10−5 | 0.304 |
P-6 | −0.749 | 3.107 × 10−5 | 0.364 |
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Zhang, C.; Li, Y.; Xu, X.; Zhang, M.; Leng, H.; Sun, B. Optimization of Plating Process on Inner Wall of Metal Pipe and Research on Coating Performance. Materials 2023, 16, 2800. https://doi.org/10.3390/ma16072800
Zhang C, Li Y, Xu X, Zhang M, Leng H, Sun B. Optimization of Plating Process on Inner Wall of Metal Pipe and Research on Coating Performance. Materials. 2023; 16(7):2800. https://doi.org/10.3390/ma16072800
Chicago/Turabian StyleZhang, Chenming, Yongfeng Li, Xiaochang Xu, Mingming Zhang, Haoyuan Leng, and Bin Sun. 2023. "Optimization of Plating Process on Inner Wall of Metal Pipe and Research on Coating Performance" Materials 16, no. 7: 2800. https://doi.org/10.3390/ma16072800