Study the Wear Characteristics for Ni-ZrO2 and Ni-Al2O3 Nanocomposite Coatings Produced by Electroless Deposition Technique

Abstract

Metal matrix nanocomposite coatings are promising for tribological applications given their superior hardness and wear resistance compared to metals. The point of this study was to describe the shape and long-term performance of nickel-based coatings that were put on stainless steel using electroless codeposition and made stronger with nanoparticles of zirconia (ZrO₂) and alumina (Al₂O₃). Scanning electron microscopy showed the uniform incorporation of nanoceramics within nickel matrices. Pin-on-disk tribotests evaluated wear performance across loads from 5 to 15 N and sliding speeds up to 480 cm/min. Increasing nanoparticle content from 2 to 4 g/L markedly reduced wear rate due to enhanced hardness and density. At all tested loads, Ni-ZrO₂ and Ni-Al₂O₃ nanocomposites exhibited considerably lower wear than monolithic nickel. The nanometal matrix particles hindered plastic deformation, with weight losses up to 68% lower than base nickel. Initially, wear resistance rose proportionally with sliding speed resulting from protective oxide layers until abrasive wear prevailed. The nanoparticle reinforcement dramatically extended durability, making it ideal for tribological systems involving mixed or abrasive conditions. More research needs to be done to find the best compositions and other matrix materials to use for these nanoscale strengthening effects.