Electroless coating of Permalloy powder and DC-resistivity of alloy composites

A high-resistivity coating of Permalloy (Ni–17.81Fe–1.97Mo wt.%) powders for soft magnetic composites, SMC, was developed and characterized. The coating was made using the electroless plating method employing an aqueous solution of sodium and nickel phosphates. The chemical process led to the formation of a layer up to 1 μm thick deposited on each particle surface and composed of a mixture of Ni(OH)₂, P₂O₅ and NaPO₃ compounds, as shown by X-ray photoelectron spectrometry and X-ray powder diffraction studies. The effect of coating on electrical DC resistivity was evaluated on SMC obtained mixing the metal, coated or uncoated, and thermoplastic polymer PEEK (polyetheretherketone) powders, pressing the mixture at 800 MPa and heating in air up to melting the polymer (380–410 °C). The SMC made with coated powders showed an increase in resistivity of more than two orders of magnitude compared to that obtained with uncoated powders when the polymer ranged between 0.5 and 1.5 wt.%. This difference prevails in comparison with sintered materials processed at the same pressure and sintering in hydrogen at 1350 °C. Thus, this process would restrict the eddy currents which affect the performance of soft magnetic products for AC applications.     

Electroless Nickel Plating of Iron Powders

This work illustrates the technical feasibility of the electroless nickel plating of iron powders. The coated powders exhibit a high level of homogeneity and the sintered compacts have good mechanical properties. Decreasing powder size increases the nickel concentration and improves diffusion by particle-to-particle contact. Alloying is promoted by reducing diffusion distances.     

复合稀土氧化物掺杂W-20Cu复合材料的制备及组织性能研究

以偏钨酸铵和硝酸铜为原料,采用EDTA-柠檬酸法制备了含有0~0.8wt.%稀土氧化物( Ce_0.8Sm_0.2O_1.9, SDC)的W-20Cu复合粉体,所制备的复合粉体经压制成型、1250°C烧结2h后获得SDC/W-20Cu复合材料烧结体。对所制备复合粉体进行物相、形貌的表征;研究稀土氧化物的添加对SDC/W-20Cu烧结体的密度、组织结构和物理力学性能的影响。实验结果表明：所制备的W-Cu复合粉体平均粒度为100~200nm;同时,SDC的添加对烧结体的密度和电导率会有轻微的影响,但能够抑制晶粒的长大并明显改善烧结体的力学性能。经1250°C烧结后,SDC/W-20Cu烧结体的相对密度均高于97%;当SDC的添加量为0.6%时,具有最大的抗弯强度和显微硬度,分别是1128MPa和258HV;此外,在室温和600°C的测试条件下,其最大的抗拉强度可以达到580MPa和258MPa。     

Sintered Cu Alloyed Stainless Steels and Their Corrosion Behavior

Copper is an effective element to activate the sintering process of stainless steels and to enhance corrosion resistance of the sintered specimens. Ways of introducing Cu into stainless steel powders lead to different consequence in the microstructure and corrosion behavior of sintered Cu alloyed stainless steel. In the present work, two methods, mixing Cu with stainless steel powder and coating stainless steel powder with Cu by electroless plating, were introduced in order to investigate their influence on the sintered specimens. It was found that the sintered specimens from Cu-coated stainless steel powders (1-5 wt.%Cu) produce less porous surfaces with isolated pores than the specimens from mixed powders and the former have obviously high density and relatively even Cu distribution. Potentiodynamic polarization measurements indicate that Cu-electroless plating of 1-5 wt.%Cu improves the corrosion resistance of sintered stainless steel due to the lowering of passivation current density.     

Thermal properties of W–Cu composites manufactured by copper infiltration into tungsten fiber matrix

W–Cu composites were produced by the technique of copper infiltration into tungsten fiber preforms (CITFP) under vacuum circumstance. Fibrous structure preforms with various volume fraction of tungsten fiber were fabricated by the process of mold pressing and sintering. The molten copper was infiltrated into the open pores of the preforms under vacuum at 1473 K to 1573 K for 1 h to produce W–Cu composites with compositions of 10–30 wt.% copper balanced with tungsten. The microstructure, relative densities, and thermal properties of the composites were investigated and measured. The relative as-sintered density was enhanced with the increase of the sintering temperature. The thermal conductivity of the W–Cu30 composite with 28.2 wt.% Cu was 241 W/(m · K) at 298 K, 10% higher than that of the W–Cu alloy with similar copper content produced by conventional powder metallurgy process. The thermal expansion of the composites was decreased with the increase of tungsten content, keeping the same tendency as the prediction by the rule of weighted average of volume ratio of compositions.     

低W-W连接度65W-25Cu-10Ni合金的制备及准静态力学性能研究

利用W颗粒表面化学镀Ni结合SPS的方法,制备了低W-W连接度65W-25Cu-10Ni合金,并开展了准静态力学性能研究。结果表明,制得的Ni包W复合粉中Ni包覆层分布均匀且与W结合良好;以Ni包W复合粉和Cu粉为原料制备的65W-25Cu-10Ni合金组织均匀且致密。在准静态压缩加载条件下,与65W-35Cu合金相比,65W-25Cu-10Ni合金的强度及塑性均大幅度提高;在准静态拉伸加载条件下,与65W-35Cu合金相比,65W-25Cu-10Ni合金的强度较高,塑性没有明显提高。机理分析表明,与65W-35Cu合金相比,65W-25Cu-10Ni合金中W-W连接度较低、粘结相由Cu相转变为Cu0.81Ni0.19固溶体,且W与粘结相之间形成了冶金结合,以上三个因素共同导致65W-25Cu-10Ni合金强度的提高;此外,W-W连接度的降低以及W-粘结相界面结合强度的提高是65W-25Cu-10Ni合金在准静态压缩加载条件下塑性提高的原因。     

The comparison of W/Cu and W/ZrC composites fabricated through hot-press

In this study the W/Cu and W/ZrC composites have been fabricated by hot-press and then their mechanical properties were compared in addition to their ablation resistance. To produce W-20vol.%Cu composite at first stage the elemental W and Cu powders were ball milled for 3 h in rotation speed of 200 rpm, in which 2% nickel was added in order to reduce the density. The mixed powders were hot-pressed for 1 h at 1400 °C and compact pressure of 30 MPa. Additionally W/40vol.%ZrC composite has been fabricated by hot-pressing of mixed W and ZrC powders in 30 MPa and 2200 °C for 1 h. Since these materials are used at elevated temperature applications, where ablation is the main source of material failure, after producing the composites their ablation resistance was evaluated in a real condition. The results show that not only W–ZrC composite is better than W–Cu composite in mechanical properties, but also in ablation resistance.     

The effect of sintering temperature on densification of nanoscale dispersed W–20–40%wt Cu composite powders

Nanoscale dispersed particles of W–20–40%wt Cu were synthesized using a chemical procedure including initial precipitating, calcining the precipitates and reducing the calcined powders. The powders were characterized using X-ray diffraction and map analyses. The effect of sintering temperature was investigated on densification and hardness of the powder compacts. Relative densities more than 98% were achieved for the compacts which sintered at 1200 °C. The results showed that in the case of W–20%wt Cu composite powders, the hardness of the sintered compacts increased by elevating the sintering temperature up to 1200 °C while for the compacts with 30 and 40%wt Cu, the sintered specimens at 1150 °C had the maximum hardness value. The microstructural evaluation of the sintered compacts by scanning electron microscopy showed homogenous dispersion of copper and tungsten and a nearly dense structure. A new proposal for the variation of the mean size and morphologies of W-particles with volume percent of copper melt within the composites has been suggested.     

Self-lubricating ceramic cutting tool material with the addition of nickel coated CaF2 solid lubricant powders

A new type of self-lubricating ceramic cutting tool material with the addition of metal coated solid lubricant powders was developed. Nickel coated CaF₂ composite powders with core–shell structure were produced by electroless plating technique. The growth process of nickel coating on the solid lubricant CaF₂ powders was analyzed. The as-prepared self-lubricating ceramic cutting tool material made by adding nickel coated CaF₂ powders exhibited notable improvements in microstructure and mechanical properties, in comparison with the corresponding cutting tool material made by directly adding uncoated CaF₂ powders. Cutting tests show that the new type of self-lubricating ceramic cutting tool has better antifriction property and wear resistance than the corresponding cutting tool.     

Sintering behavior of W–30Cu composite powder prepared by electroless plating

Powder metallurgy technique was employed to prepare W–30 wt.% Cu composite through a chemical procedure. This includes powder pre-treatment followed by deposition of electroless Cu plating on the surface of the pre-treated W powder. The composite powder and W–30Cu composite were characterized by X-ray diffraction (XRD) and field emission scanning electron microscopy (FE-SEM). Cold compaction was carried out under pressures ranging from 200 MPa to 600 MPa while sintering at 850 °C, 1000 °C and 1200 °C. The relative density, hardness, compressive strength, and electrical conductivity of the sintered samples were investigated. The results show that the relative sintered density of the titled composites increased with the sintering temperature. However, in solid sintering, the relative density increased with pressure. At 1200 °C and 400 MPa, the liquid-sintered specimen exhibited optimum performance, with the relative density reaching as high as 95.04% and superior electrical conductivity of IACS 53.24%, which doubles the national average of 26.77%. The FE-SEM microstructure evaluation of the sintered compacts showed homogenous dispersion of Cu and W and a Cu network all over the structure.     

不同形状钨粉化学镀铜的研究

通过化学镀法制备铜包钨复合粉末,研究不规则形状的钨粉以及经等离子球化处理的球形钨粉的化学镀铜。结果表明,对于颗粒形貌不规则棱角分明的破碎钨粉,经化学镀包覆后粉末没有明显的棱角,表面粗糙。而经等离子球化处理后球形度较高的球形粉,颗粒表面存在缺陷,化学镀后粉末的球形度没有明显的变化,化学镀层在其表面沉积均匀,且钨粉表面质量得到改善,不存在表面缺陷。化学镀后复合粉末在600℃下进行氢气退火处理后,镀层上的粗糙的表面变得平滑,镀层中的空隙明显减少,形成了一层均匀致密的铜层包覆在钨颗粒表面。     

A new process for preparing conducting wood veneers by electroless nickel plating

A new, simple electroless Ni-P plating process for preparing a conductive wood veneer has been developed. In this process, the activation was combined with electroless deposition in the plating solution. This provides a simple, environmentally friendly method, by which a Ni-P layer was successfully deposited on the surface of Manchurian ash veneer. It was observed by scanning electron microscopy that the deposited layer was uniform, compact and continuous. Results from energy-dispersive spectroscopy showed that a low-phosphorus layer was obtained, which contained about 4 wt.% phosphorus and 96 wt.% nickel. X-ray diffraction analysis indicated that the coating was crystalline. It is considered that the crystalline structure is related to the low-phosphorus content of the layer. Veneers plated with the crystalline Ni-P coating had good electrical conductivity, with a surface resistivity less than 200 mΩ/cm² and a firm adhesion of the Ni-P coating to the wood.     

The effect of additive and sintering mechanism on the microstructural characteristics of W–40Cu composites

In this research, effect of cobalt and nickel additives on the W–40wt.% Cu composites prepared by solid phase sintering and infiltration (SPS + I) as well as liquid phase sintering (LPS) processes has been investigated. For this purpose, three types of powder consist of pure tungsten, mixture of tungsten–1wt.%Co and mixture of tungsten-1wt.%Ni were separately prepared and compacted by cold isostatic pressing (CIP). In the SPS + I process, compacted specimens were sintered at 1100 °C for 1 h and subsequently infiltrated by liquid copper at 1250 °C for 1 h. In the LPS process, compacted samples were directly infiltrated without initial sintering. Density of samples was measured by Archimedes method. Microstructure (i.e. contiguity, porosity, grain size) and chemical composition were studied by SEM and EDS, respectively. It is found that microstructural characteristics of the W–40wt.%Cu composites depend on sintering mechanism as well as additive type. Density of samples prepared by LPS process was higher in compared with ones obtained via SPS + I process. This behavior was related to W–W contiguity as well as tungsten particles wettability.     

Investigation on the characteristics of micro- and nano-structured W-15 wt.%Cu composites prepared by powder metallurgy route

The properties of W-15 wt.%Cu composites were investigated by preparing two distinct composites of micrometer and nanoscale structures. Micrometer composite was produced by mixing elemental W and Cu powders and nanometer one was synthesized through a mechanochemical reaction between WO₃ and CuO powders. Subsequent compaction and sintering process was performed to ensure maximum possible densification at 1000-1200 °C temperatures. Finally, the behavior of produced samples including relative density, hardness, compressive strength, electrical conductivity, coefficient of thermal expansion (CTE) and room temperature corrosion resistance were examined. Among the composites, nano-structured sample sintered at 1200 °C exhibited better homogeneity, the highest relative density (94%) and mechanical properties. Furthermore, this composite showed superior electrical conductivity (31.58 IACS) and CTE (9.95384 × 10^- 6) in comparison with micrometer type. This appropriate properties may be mainly attributed to liquid phase sintering with particle rearrangement which induced by higher capillary forces of finer structures.     

Corrosion and wear-corrosion resistance properties of electroless Ni-P coatings on GFRP composite in wind turbine blades

Electroless nickel (EN) coatings with phosphorus are preferred in many industries such as the oil, chemical, plastic, mechanical, and electronic industries because of their excellent corrosion and wear resistance. This work evaluates the corrosion and wear-corrosion resistance of electroless nickel-phosphorus (ENP) coatings on glass fiber-reinforced plastic (GFRP) composites that are frequently used in wind turbine blades. The results demonstrated that the micro-porosity, phosphorus content, thickness and corrosion and wear-corrosion properties of ENP coatings on the GFRP substrate were all strongly related to the grinding pre-treatment condition, meaning the corresponding surface roughness state of the substrate. A higher P content (P > 7 wt.%), lower micro-porosity, greater thickness and greater hardness of the ENP coatings on GFRP substrate were obtained as the surface roughness of the substrate increased over 0.3 µm (as it did upon grinding with emery paper of lower than 800-grade), improving corrosion and wear-corrosion resistance properties.     

Electroless Ni-P plating on Mg-10Gd-4.8Y-0.6Zr magnesium alloy with a new pretreatment process

A new pretreatment process for electroless Ni-P plating on Mg-10Gd-4.8Y-0.6Zr was investigated in this paper. The morphology, component, chemical composition and structure of the pretreatment layers and Ni-P coating were analyzed by scanning electronic microscopy, energy dispersive spectroscopy and X-ray diffraction spectroscopy. The structure of Ni-P coating was also detected by transmission electron microscopy (TEM). Potentiodynamic polarization analysis and salt spray test were used to test the corrosion resistance of the Ni-P coating. Experimental results indicate that: metal Cr generated in the new pretreatment process, which provided active points for later zinc immersion process, was beneficial to nickel deposition. The subsequent Ni-P coating was amorphous, in which the content of P was 9.43 wt.%. It was uniform and its thickness reached about 50 μm at 2 h deposition. Compared to Mg-10Gd-4.8Y-0.6Zr alloy substrate, the corrosion potential of the coated alloy shifted by 1090 mV positively and the corrosion current density decreased one order of magnitude in 3.5 wt.% NaCl solution. The salt spray test time of Ni-P coating was 210 h. All of these results suggest that the electroless nickel plating procedure researched in this paper is suitable for Mg-10Gd-4.8Y-0.6Zr alloy.     

Effects of pre-treatments on the corrosion properties of electroless Ni-P layers deposited on AlMg2 alloy

Amorphous Ni-P layers with 8-10 wt.% phosphorus were deposited by sodium hypophosphite onto AlMg2 type aluminium alloy substrates after different pre-treatments. Prior to the electroless nickel-phosphorus (ENP) deposition in an acetate and lactic acid based nickel bath, the widely applied Zn (zincate) or Ni displacement (Ni strike) pre-treatments for aluminium substrates as well as a non-conventional surface conditioning one (soaking in a warm solution containing only hypophosphite and lactic acid) were all tested and their effects evaluated on the corrosion and other properties of the Ni-P layers developed right afterwards. The surface morphology and structure of the ENP layers were characterized by scanning electron microscopy and X-ray diffraction analysis. Polarization resistances were measured in 0.5 mol dm^− 3 Na₂SO₄ solution at pH 3. Compared to the direct electroless plating on the bare aluminium alloy AlMg2, it was found, that the hypophosphite adlayer (hypophosphite immersion pre-treatment) have also increased the corrosion resistance as the displacement pre-coatings, but without decreasing the deposition rate unlike conventional displacement methods. In the studied ENP deposition systems the decrease of corrosion rate could mainly be attributed to the lower microporosity and smoother morphology of the nickel-phosphorus coatings.     

Preparation and Properties of W-15Cu Composite by Electroless Plating and Powder Metallurgy

用化学镀和粉末冶金的方法制备出W-15Cu复合材料。首先用化学方法对W粉表面预处理,然后在其表面化学镀铜。得到的复合粉末用图谱进行表征。发现用化学镀的方法制备出的W-15Cu复合粉末纯度非常高,且W颗粒均匀、被Cu致密的包覆着。呈现出包状结构。这种复合粉末表现出优异的压制性能,压坯分别在300, 400, 500, 600 MPa的压制压力下成形。压坯在1250 ℃温度下保温90 min烧结后,从其断口形貌可以发现W颗粒没有明显的长大,且W颗粒表面特征并没有发生改变,仍然表现出预处理后的表面特征。对烧结体的相对密度、硬度、抗弯强度和电导率同样进行了表征     

The effect of submicron-sized initial tungsten powders on microstructure and properties of infiltrated W-25 wt.% Cu alloys

In the present work, several W-25 wt% Cu alloys have been prepared through combined processes of high-energy ball-milling, liquid-phase sintering and infiltration, using the precursors of industrial copper powders with an average particle size of 50 μm and tungsten powders with alternative average particle size of 8 μm, 800 nm, 600 nm or 400 nm. Microstructure characteristics, relative density, hardness and electrical conductivity of the WCu alloys were investigated to elucidate the effect of initial particle size of tungsten powders. EBSD was further utilized to reveal the orientation and grain size distribution in the WCu alloys prepared by 8 μm and 400 nm-sized tungsten powders. The results showed that the WCu alloy made by 400 nm-sized tungsten powders exhibited excellent homogeneity for both sintered tungsten powders and grains, together with the highest relative density of 98.9%, the highest hardness of 230 HB, and good electrical conductivity of 48.7% IACS. Moreover, it also showed highly improved arc erosion and mechanical wear resistances.     

Evaluation of cyclic hot corrosion behaviour of detonation gun sprayed Cr3C2-25%NiCr coatings on nickel- and iron-based superalloys

In the present investigation, Cr₃C₂-NiCr cermet coatings were deposited on two Ni-based superalloys, namely superni 75, superni 718 and one Fe-based superalloy superfer 800H by detonation-gun thermal spray process. The cyclic hot-corrosion studies were conducted on uncoated as well as D-gun coated superalloys in the presence of mixture of 75 wt.% Na₂SO₄ + 25 wt.% K₂SO₄ film at 900 °C for 100 cycles. Thermogravimetric technique was used to establish the kinetics of hot corrosion of uncoated and coated superalloys. X-ray diffraction, FE-SEM/EDAX and X-ray mapping techniques were used to analyze the corrosion products for rendering an insight into the corrosion mechanisms. It was observed that Cr₃C₂-NiCr-coated superalloys showed better hot-corrosion resistance than the uncoated superalloys in the presence of 75 wt.% Na₂SO₄ + 25 wt.% K₂SO₄ film as a result of the formation of continuous and protective oxides of chromium, nickel and their spinel, as evident from the XRD analysis.