AZ91D镁合金化学镀Ni-P/Ni-W-P复合镀层的研究
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摘要
本文着眼于提高镁合金的耐腐蚀性能,以获得良好的镁合金化学镀镍层为目的。镁合金试样在化学镀镍前首先在铬酸和硝酸溶液中进行铬化处理,然后将其浸在氟化氢溶液中使其表面生成氟化镁保护膜,采用硫酸镍为主盐的镀液在AZ91D镁合金上直接化学镀Ni-P合金,镀层致密无孔,具有一定耐蚀性。在此镍磷合金的基础上,提出了一种镁合金化学镀Ni-P/Ni-W-P复合镀层的方法;然后,通过调整三元合金镀液的pH值,研究了不同pH值的溶液对于复合镀层耐蚀性的影响。实验发现,随着镀液pH值升高,镀层中W含量逐渐升高,P含量基本不变,镀层腐蚀电位随W含量增加而变正;三种复合镀层的孔隙率都能在24μm以内达到零,且在pH值为5的条件下获得的镀层孔隙率最小。在10%HCl的腐蚀能力主要取决于镀层的孔隙率,在底层Ni-P厚度大约为10μm,Ni-W-P厚度分别为19μm,25μm,22μm的情况下,耐腐蚀时间依次为:170min,49min,97min。与镀层的孔隙率大小相对关系一致。结果表明,复合镀层组织致密无孔,结合力良好,具有较高的显微硬度和耐蚀性,镀层的结合力好,硬度可达686VHN,对镁合金起到很好的保护作用。
Electroless deposition process experienced numerous modifications to meet the challenging needs of a variety of industrial applications since Brenner and Riddell invented the process in 1946. Among the various types of electroless plating, electroless nickel has gained immense popularity due to their ability to provide a hard, wear and corrosion resistant surface. Hypophosphite-reduced electroless nickel plating has proved its supremacy in providing improved hardness, corrosion and wear resistance.
Magnesium alloy has low density, high strength-to-weight ratio and other good physical and mechanical characteristics. However, the application of magnesium alloys has been limited due to their undesirable properties including poor corrosion and low wear resistance. Thus, the formation of anticorrosion and high wear-resistance coatings on the surface of Mg or Mg alloys is necessary in practical applications. Since magnesium is one of the most electrochemically active metal, ordinary coatings, such as nickel, copper and zinc coatings, can only provide a physical barrier to corrosion attack of magnesium substrate. So, any coatings on magnesium alloys should be as uniform, adherent and porosity free as possible.
In order to improve the corrosion resistance of the AZ91D magnesium alloy, electroless Ni-P/ Ni-W-P duplex coatings on AZ91D magnesium alloy directly and indirectly were investigated in this paper. SEM and XRD analysis were performed to examine the microstructure and phase composition of the coatings. The corrosion resistance of the coatings was estimated by electrochemical polarization measurement and 10%HCl solution immersion test.
Direct electroless Ni-P coating of magnesium alloy was obtained from nickel sulfate plating. The magnesium alloy samples were etched first in a solution of chromate and nitric acid and than soaked in HF solution to form a conversion film before electroless nickel deposition. But chromium compounds are carcinogenic substance, which should be abstained.
An available method to obtain electrless Ni-P/Ni-W-P coatings on AZ91D magnesium alloy was discussed. The three Ni-W-P coatings have been deposited from three different solutions. With the pH value increase from 5, 7 to 9, the W content increase. The different W content, and have higher corrosion potential with W content increase. When the protective Ni-P layer is about 10μm and the three Ni-W-P coating were 14μm, the porosity is zero. As for the sample 1 with the Ni-W0.65-P8.18 coating has the best corrosion resistance. The sample can withstand in 10% HCl solution for about 170 minutes with the thickness about 18μm .It was found that the ability of corrosion resistance in 10%HCl was determined by the porosity of the coatings. The Ni-P/Ni-W-P duplex coatings with the same thickness of about 30μm can withstand in10%HCl solution for 170min, 49min and 97min, respectively.
The highest hardness of the as-deposited Ni-P/Ni-W-P duplex coatings was about 686 VHN, which is far higher than that of the AZ91D magnesium alloy substrate (about 100 VHN).
The duplex coatings are uniform and the compatibility between the layers is good. The coatings binding force is good, which could improve the corrosion resistance of the substrate. Hence it can be concluded that electroless nickel duplex coatings will be a useful replacement for Ni–P coating.
Electroless deposition process experienced numerous modifications to meet the challenging needs of a variety of industrial applications since Brenner and Riddell invented the process in 1946. Among the various types of electroless plating, electroless nickel has gained immense popularity due to their ability to provide a hard, wear and corrosion resistant surface. Hypophosphite-reduced electroless nickel plating has proved its supremacy in providing improved hardness, corrosion and wear resistance.
Magnesium alloy has low density, high strength-to-weight ratio and other good physical and mechanical characteristics. However, the application of magnesium alloys has been limited due to their undesirable properties including poor corrosion and low wear resistance. Thus, the formation of anticorrosion and high wear-resistance coatings on the surface of Mg or Mg alloys is necessary in practical applications. Since magnesium is one of the most electrochemically active metal, ordinary coatings, such as nickel, copper and zinc coatings, can only provide a physical barrier to corrosion attack of magnesium substrate. So, any coatings on magnesium alloys should be as uniform, adherent and porosity free as possible.
In order to improve the corrosion resistance of the AZ91D magnesium alloy, electroless Ni-P/ Ni-W-P duplex coatings on AZ91D magnesium alloy directly and indirectly were investigated in this paper. SEM and XRD analysis were performed to examine the microstructure and phase composition of the coatings. The corrosion resistance of the coatings was estimated by electrochemical polarization measurement and 10%HCl solution immersion test.
Direct electroless Ni-P coating of magnesium alloy was obtained from nickel sulfate plating. The magnesium alloy samples were etched first in a solution of chromate and nitric acid and than soaked in HF solution to form a conversion film before electroless nickel deposition. But chromium compounds are carcinogenic substance, which should be abstained.
An available method to obtain electrless Ni-P/Ni-W-P coatings on AZ91D magnesium alloy was discussed. The three Ni-W-P coatings have been deposited from three different solutions. With the pH value increase from 5, 7 to 9, the W content increase. The different W content, and have higher corrosion potential with W content increase. When the protective Ni-P layer is about 10μm and the three Ni-W-P coating were 14μm, the porosity is zero. As for the sample 1 with the Ni-W0.65-P8.18 coating has the best corrosion resistance. The sample can withstand in 10% HCl solution for about 170 minutes with the thickness about 18μm .It was found that the ability of corrosion resistance in 10%HCl was determined by the porosity of the coatings. The Ni-P/Ni-W-P duplex coatings with the same thickness of about 30μm can withstand in10%HCl solution for 170min, 49min and 97min, respectively.
The highest hardness of the as-deposited Ni-P/Ni-W-P duplex coatings was about 686 VHN, which is far higher than that of the AZ91D magnesium alloy substrate (about 100 VHN).
The duplex coatings are uniform and the compatibility between the layers is good. The coatings binding force is good, which could improve the corrosion resistance of the substrate. Hence it can be concluded that electroless nickel duplex coatings will be a useful replacement for Ni–P coating.
引文
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3 王渠东, 吕宜振, 曾小勒. 镁合金在电子器材壳体中的应用. 材料导报, 2000, 14(6): 22-24.
4 Brown R E. Application of magnesium alloy. Light Metal Age, 1991, 49(7-8): 6-9.
5 蒋百灵, 张淑芬, 吴国建等. 镁合金微弧氧化陶瓷层显微缺陷与相组成及其耐蚀性. 中国有色金属学报, 2002, 12(3): 454-457.
6 叶宏, 冯燕熹, 王希山. 镁合金化学镀镍工艺研究. 表面技术, 2002, 31(6): 32-36.
7 张大顺. TL-2 化学镀Ni-P合金工艺研究. 表面技术, 1999, 4: 12-16.
8 曾爱平, 薛颖, 钱宇峰等. 镁合金的化学表面处理. 腐蚀与防护, 2000, 21(2): 55-56.
9 Usk B R S.Magnisium Products design. New York: The International Magnesium Association, 1987.
10 Roehring Klaus. Taschenbuch der Giesserei-Praxis.Berlin: Fachverlag Schiele&Schoen Gmbh, 2000.
11 曹小琴,王渠东,吕宜振等,镁合金应用新进展[ J].铸造,1998 (11):39.
12 Robert L. Edgar. Global Overview on Demand and Applications for Magnesium Alloys. Magnesium Alloys and Their Applications. New York, 2000, 3-8.
13 H.Friedrich, S. Schumann. The second Age of Magnesium Research Strategies to Bring the Automotive Industry's vision to Reality. Magnesium Alloys and Their Applications. New York, 2000, 9-26.
14 H. Kuwahara, Y. Al-Abdullat, M. Ohta, S. Tsutsumi, K. Ikeuchi, N. Mazaki, T. Aizauta, Surface Reaction of Magnesium in Hank's Solutions. Materials Science Forum, 2000, 350 - 351: 349-358.
15 刘长瑞, 王伯健, 胡裕邦. 镁合金材料在电子行业中的开发应用前景. 镁铝通讯, 2001, 2: 53-55.
16 刘正. 镁合金压铸及其铸件低周疲劳行为与裂纹扩展的研究.沈阳: 中国科学院金属研究所,2001, 15-17.
17 D.S. Tawil, Corrosion and Surface Protection Developments Proceedings of ConferenceMagnesium Technology. London: Institute of Metals, 1986.
18 G.L. Makar, J.Kruger. Corrosion of magnesium. International Materials Reviews, 1993, 38(3): 138-153.
19 Y.Sakata, Electroless nickel plating directly on magnesium alloy die-castings. AESF SUR/FIN, Orlando, 1987. 1-6.
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