The effect of processing gas on corrosion performance of electroless Ni-W-P coatings treated by laser

An investigation of the microstructural and corrosion characteristics of electroless Ni-5.5 W-6.5P coatings on steel substrates after laser treatment in argon and air is presented. The microstructural characteristics of the coatings, in terms of crystallisation, grain size, microstrain, porosity as well as surface chemistry, were examined using quantitative X-ray diffraction (XRD), scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). Electrochemical tests, using potentiodynamic polarisation in 0.5 M H2SO4 solution and electrochemical impedances spectroscopy (EIS) in 3.5% NaCl solution, were undertaken to evaluate the corrosion behaviour of the coatings. The results indicated that the laser-treated coatings consisted of nanocrystalline Ni and Ni3P phases, along with retained amorphous phase; further, the dimensions of the Ni crystallites were larger than those of Ni3P. The laser-treated coating in argon revealed the presence of submicron scale porosity, while no porosity was evident in the coating surface treated by laser in air. The uniform corrosion revealed in 0.5 M H2SO4 solution is mainly determined by the microstructural characteristics of the coating. Pitting corrosion in 3.5% NaCl solution depended on the amount of porosity on the surface. The laser-treated coating in air exhibited better corrosion resistance in both acidic and chloride environments than that laser-treated in argon.

► Quantitative XRD allowed investigation of crystallinity (volume fraction, size of each phase).
► XPS analysis indicated that laser-treated coating in air contained a surface oxide film.
► Laser-treated coating in Ar had sub-micron porosity but not in the coating treated in air.
► Uniform corrosion occurred in 0.5 M H2SO4 while pitting in 3.5% NaCl solution.
► Laser-treated coating in air showed superior corrosion resistance than that in Ar.