V. Ezhil Selvi

Bio: V. Ezhil Selvi is an academic researcher from National Aerospace Laboratories. The author has contributed to research in topics: Corrosion & Dielectric spectroscopy. The author has an hindex of 10, co-authored 12 publications receiving 817 citations.

Corrosion resistance and Microstructure of electrodeposited nickel-cobalt alloy coatings

Abstract: Ni–Co alloys with varying cobalt content were electrodeposited employing sulphamate electrolyte. The changes in microstructure and corrosion behavior of electrodeposited nickel with respect to cobalt addition were studied. Scanning electron microscope, optical microscope and energy dispersive X-ray analysis were used to characterize the alloy coatings. The alloy co-deposition was observed to be anomalous type. The cross-section microhardness measurement indicated that the hardness reached the maxima for a cobalt content of 50 wt.% and then dropped with the increase in cobalt content. A correlation between microhardness and microstructure has been attempted. The optical micrographs indicated a change in microstructure from mixed columnar-fibrous to lamellar and finally to fibrous with increase in cobalt content. The X-ray diffraction (XRD) studies indicated the crystal structure to be cubic for cobalt content in the range of 0–50 wt.%. A transition to hexagonal structure was observed for a cobalt content of 70 wt.% and beyond. A change in preferred orientation was also observed with respect to cobalt addition. Potentiodynamic polarization and electrochemical impedance studies were used to study the corrosion behavior of Ni–Co alloys. The physical behavior was quantified with equivalent circuit. These studies indicated that the Ni–20% Co alloy exhibited better corrosion resistance in comparison to other Ni–Co alloys, plain nickel and plain cobalt coatings irrespective of the substrate (mild steel, brass) employed for deposition.

Electrochemical behavior of single layer CrN, TiN, TiAlN coatings and nanolayered TiAlN/CrN multilayer coatings prepared by reactive direct current magnetron sputtering

Abstract: The corrosion behaviors of single layer TiN, CrN, TiAlN and multilayer TiAlN/CrN coatings, deposited on steel substrate using a multi-target reactive direct current magnetron sputtering process, were studied in 3.5% NaCl solution by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The total thickness of the coatings was about 1.5 μm. About 0.5 μm thick chromium interlayer was used for improved adhesion of the coatings. The potentiodynamic polarization measurements showed that for all the coatings the corrosion potential shifted to higher values as compared to the uncoated substrate. Similarly, the corrosion current density decreased for coated samples, indicating better corrosion resistance of the coated samples. The multilayer coatings of TiAlN/CrN exhibited superior corrosion behavior as compared to the single layer coatings. The Nyquist and the Bode plots obtained from the EIS measurements were fitted by appropriate equivalent circuits to calculate the pore resistance, the charge transfer resistance and the capacitance. These studies revealed that the pore resistance was lowest for TiN coatings, which increased for TiAlN coatings. TiAlN/CrN multilayer coatings exhibited highest pore resistance. No significant change in the capacitive behavior of the coatings was observed, suggesting minimal morphological changes as a result of immersion in the electrolyte. This could be attributed to shorter immersion durations. These studies were confirmed by examining the corroded samples under scanning electron microscope. Preliminary experiments conducted with additional interlayer of electroless nickel (5.0 μm thick) have shown significant improvement in the corrosion resistance of the coatings.

Electrochemical studies on electroless ternary and quaternary Ni-P based alloys

Abstract: The autocatalytic (electroless) deposition of Ni–P based alloys is a well-known commercial process that has found numerous applications because of their excellent anticorrosive, wear, magnetic, solderable properties, etc. It is a barrier coating, protecting the substrate by sealing it off from the corrosive environments, rather than by sacrificial action. The corrosion resistance varies with the phosphorus content of the deposit: relatively high for a high-phosphorus electroless nickel deposit but low for a low-phosphorus electroless nickel deposit. In the present investigation ternary Ni–W–P alloy films were prepared using alkaline citrate-based bath. Quaternary Ni–W–Cu–P films were deposited by the addition of 3 mM copper ions in ternary Ni–W–P bath. X-ray diffraction (XRD) studies indicated that all the deposits were nanocrystalline, i.e. 1.2, 2.1 and 6.0 nm, respectively, for binary, ternary and quaternary alloys. Corrosion resistance of the films was evaluated in 3.5% sodium chloride solution in non-deaerated and deaerated conditions by potentiodynamic polarization and electrochemical impedance (EIS) methods. Lower corrosion current density values were obtained for the coatings tested in deaerated condition. EIS studies showed that higher charge transfer resistance values were obtained for binary Ni–P coatings compared to ternary or quaternary coatings. For all the coatings a gradual increase in the anodic current density had been observed beyond 740 mV. In deaerated condition all the reported coatings exhibited a narrow passive region and all the values of Ep, Etp and ipass were very close showing no major changes in the electrochemical behavior. In the non-deaerated conditions no passivation behavior had been observed for all these coatings.

Synthesis and properties of electrodeposited Ni/ceria nanocomposite coatings

Abstract: Composite plating is a method of co-depositing fine particles of metallic or non-metallic compounds or polymers in the plated layer to improve material properties such as lubrication, wear resistance and corrosion resistance. In the present study, Ni was chosen as the matrix material and ceria nanoparticles were chosen as the distributed phase. Nanocrystalline ceria powder was synthesized by the solution combustion process and characterized by powder X-ray diffractometry (XRD), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The nanosize ceria particles were co-deposited with nickel from a nickel sulfamate bath using conventional electrodeposition method. The electrodeposition was carried out at current densities of 0.23, 0.77, 1.55, 3.1 and 5.4 A/dm2. The microhardness of the Ni matrix was enhanced by the incorporation of ceria particles. Potentiodynamic polarization, electrochemical impedance spectroscopy and SEM were used to characterize the corrosion behaviour of Ni and Ni/CeO2 coatings. These studies showed improved corrosion resistance for Ni/CeO2 when compared to Ni. The microhardness, corrosion resistance and wear resistance of Ni and Ni/CeO2 were compared.

Effect of electroless nickel interlayer on the electrochemical behavior of single layer CrN, TiN, TiAlN coatings and nanolayered TiAlN/CrN multilayer coatings prepared by reactive dc magnetron sputtering

Abstract: The electrochemical behavior of single layer TiN, CrN, TiAlN and multilayer TiAlN/CrN coatings, deposited on steel substrates using a multi-target reactive direct current (dc) magnetron sputtering process, was studied in 3.5% NaCl solution. The total thickness of the coatings was about 1.5 μm. About 0.5 μm thick chromium interlayer was used to improve adhesion of the coatings. With an aim to improve the corrosion resistance, an additional interlayer of approximately 5 μm thick electroless nickel (EN) was deposited on the substrate. Potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) were used to study the corrosion behavior of the coatings. Scanning electron microscopy and energy dispersive X-ray analysis were used to characterize the corroded samples. The potentiodynamic polarization tests showed lower corrosion current density and higher polarization resistance (Rp) for the coatings with EN interlayer. For example, the corrosion current density of TiN coated steel was decreased by a factor of 10 by incorporating 5 μm thick EN interlayer. Similarly, multilayer coatings of TiAlN/CrN with EN interlayer showed about 30 times improved corrosion resistance as compared to the multilayers without EN interlayer. The porosity values were calculated from the potentiodynamic polarization data. The Nyquist and the Bode plots obtained from the EIS data were fitted by appropriate equivalent circuits. The pore resistance (Rpore), the charge transfer resistance (Rct), the coating capacitance (Qcoat) and the double layer capacitance (Qdl) of the coatings were obtained from the equivalent circuit. Multilayer coatings showed higher Rpore and Rct values as compared to the single layer coatings. Similarly, the Qcoat and Qdl values decreased from uncoated substrate to the multilayer coatings, indicating a decrease in the defect density by the addition of EN interlayer. These studies were confirmed by examining the corroded samples under scanning electron microscopy.

Combustion synthesis and nanomaterials

Abstract: The recent developments and trends in combustion science towards the synthesis of nanomaterials are discussed. Different modifications made to conventional combustion approaches for preparation of nanomaterials are critically analyzed. Special attention is paid to various applications of combustion synthesized nanosized products.

Tribology of electroless nickel coatings – A review

Abstract: Electroless coating is different from the conventional electrolytic coating as the former does not require any electricity for its operation. The advantages include uniform coating and also nonconductive materials can be coated. Electroless nickel coatings possess splendid tribological properties such as high hardness, good wear resistance and corrosion resistance. For this reason, electroless nickel has found wide applications in aerospace, automobile, electrical and chemical industries. Quest for improved tribological performances has led many researchers to develop and investigate newer variants of electroless nickel coatings like Ni–W–P, Ni–Cu–P, Ni–P–SiC, Ni–P–TiO2, and so on. Also the enhancement of tribological characteristics through modification of the coating process parameters has remained a key point of interest in researchers. The technological advancement demands the development of newer coating materials with improved resistance against wear and tear. Electroless nickel has shown huge potential to fit in that space and so the study of its tribological advancement deserves a thorough and exhaustive study. The present article reviews mainly the tribological advancement of different electroless nickel coatings based on the bath types, structure and also the tribo testing parameters in recent years.

A comparative study of reactive direct current magnetron sputtered CrAlN and CrN coatings

Abstract: Approximately 1.5 μm thick CrN and CrAlN coatings were deposited on silicon and mild steel substrates by reactive direct current (DC) magnetron sputtering. The structural and mechanical properties of the coatings were characterized using X-ray diffraction (XRD) and nanoindentation techniques, respectively. The bonding structure of the coatings was characterized by X-ray photoelectron spectroscopy (XPS). The surface morphology of the coatings was studied using scanning electron microscopy (SEM) and atomic force microscopy (AFM). The XRD data showed that the CrN and CrAlN coatings exhibited B1 NaCl structure. Nanoindentation measurements showed that as-deposited CrN and CrAlN coatings exhibited a hardness of 18 and 33 GPa, respectively. Results of the surface analysis of the as-deposited coatings using SEM and AFM showed a more compact and dense microstructure for CrAlN coatings. The thermal stability of the coatings was studied by heating the coatings in air from 400 to 900 °C. The structural changes as a result of heating were studied using micro-Raman spectroscopy. The Raman data revealed that CrN coatings got oxidized at 600 °C, whereas in the case of CrAlN coatings, no detectable oxides were formed even at 800 °C. After annealing up to 700 °C, the CrN coatings displayed a hardness of only about 7.5 GPa as compared to CrAlN coatings, which exhibited hardness as high as 22.5 GPa. The potentiodynamic polarization measurements in 3.5% NaCl solution indicated that the CrAlN coatings exhibited superior corrosion resistance as compared to CrN coatings.

Preparation and corrosion behavior of Ni and Ni–graphene composite coatings

Abstract: The graphite oxide was synthesized using the Hummers method, and then it was reduced by hydrazine hydrate to obtain graphene. It was characterized with UV (ultra violet), IR (infra red), XRD (X-ray diffraction) spectra and SEM (scanning electron microscope) images. The composite coating of Ni–graphene on mild steel specimens was obtained by the electrodeposition technique. The composite coating was subjected to various electrochemical tests to know its corrosion behavior and compared with pure Ni coating. The EIS (electrochemical impedance spectroscopy) was performed to confirm the corrosion resistance property. The composite film was studied by recording its XRD and SEM. The crystallite size, texture coefficients and hardness of coating was measured.

Low-temperature atomic layer deposition of Al2O3 thin coatings for corrosion protection of steel: Surface and electrochemical analysis

Abstract: ToF-SIMS, XPS, voltammetry and EIS investigation of the anti-corrosion properties of thin (10, 50 and 100 nm) alumina coatings grown by atomic layer deposition at 160 °C on steel is reported. Surface analysis shows a thickness-independent Al2O3 stoichiometry of the coating and trace contamination by the growth precursors. The buried coating/alloy interface has iron oxide formed in ambient air and/or resulting from the growth of spurious traces in the initial stages of deposition. Electrochemical analysis yields an exponential decay of the coating porosity over four orders of magnitude with increasing thickness, achieved by sealing of the more defective first deposited 10 nm.