Preparation of coatings with high adhesion strength and high corrosion resistance on sintered Nd–Fe–B magnets through electroless plating

Electroless Ni–P-based coatings have been deposited on sintered Nd–Fe–B magnets through applying ultrasonic irradiation and adjusting the [Cu2+]/[Ni2+] ratio in the solution. The effects of the ultrasonic power on the adhesion to the magnet substrate and the [Cu2+]/[Ni2+] ratio on the corrosion resistance of the coatings were investigated. It was found that the adhesion of the coating to the substrate could be greatly improved through applying ultrasonic irradiation. Maximum adhesion strength reached 56 MPa at 150 W. The results also showed that the addition of Cu2+ could improve the corrosion resistance of Ni–P-based coatings. When the [Cu2+]/[Ni2+] ratio was 0.02, the coating could be as long as 512 h free of corrosion in the neutral salt spray. The compact amorphous structure was responsible for the improved corrosion resistance of the coating.