High Temperature Tribological Behavior of Electroless Plating Ni-P-Si3N4-WS2 Composite Coatings

Abstract

Electroless nickel composite coatings have the potential for high-temperature tribological applications, and a combination of high wear resistance and low friction factor is one of the desirable solutions but still a tricky problem. The addition of self-lubricating WS2 and hard Si3N4 nanoparticles to the Ni-P coatings is expected to obtain good high-temperature tribological performance. In this work, Ni-P-Si3N4-WS2 composite coatings with various contents of WS2 nanoparticles were prepared using electroless plating and subsequently annealed at 400 °C in an inert atmosphere. The tribological properties of the coatings were evaluated using a ball-on-disc wear instrument at operating temperatures from 25 to 600 °C. The microstructure, chemical composition, and surface morphology of the coatings were characterized by X-ray diffractometry (XRD), energy disperse spectroscopy (EDS), and scanning electron microscopy (SEM). Upon increasing the WS2 dosage in the bath, the WS2 content in the coating increased and the micro-hardness of the as-plated coating increased from 539 to 717 HV. After heat treatment, the coating underwent a crystallization process, and the hardness increased from 878 to 1094 HV. The main wear mechanism of the coating changed from adhesive wear in the as-plated state to abrasive wear in the annealed state. The annealed Ni-P-Si3N4-WS2 coating with a WS2 dosage of 2.5 g/L in the bath exhibited excellent mechanical properties, with a hardness of 10.9 GPa, a friction coefficient of ~0.51, and a wear rate of 8.4 × 10−15 m3N−1⋅m−1 at room temperature, and maintained optimal performance at high temperatures. At operating temperatures of 200, 400, and 600 °C, the form of wear was adhesive wear for coatings with a WS2 dosage <1.5 g/L and abrasive wear for coatings with a WS2 dosage ≥1.5 g/L. The synergism of WS2 and Si3N4 particles refined the grains of the Ni-P matrix in as-plated coatings and obviously reduced the friction coefficient of friction pairs in annealed coatings at all operating temperatures.