Effect of substrate’s surface roughness on corrosion and wear rate of Ni-GO nanocomposite coating

Abstract

Corrosion is a natural process that occurs when refined metal is converted into a more stable form, such as oxide, hydroxide, or sulfide. Wear is the failure of a surface due to dynamic contact between two surfaces. In offshore operations and environments, corrosion and wear are major problems due to the presence of corrosive and abrasive elements. The coating is a common surface protection method that enhances corrosion resistance and prolongs lifespan. In this work, a Ni-Graphene nanocomposite coating was fabricated using the electrodeposition method. This work aimed to fabricate a Ni-GO nanocomposite coating on mild steel with different surface roughness, to characterize the physical, mechanical, and chemical properties of the coating, and to investigate its corrosion and wear rate. The fabrication process involved preparing substrates coated with Ni-GO nanocomposite through a 45-minute constant current electrodeposition process. The coated specimens were characterized using X-Ray Diffraction Machine (XRD), Scanning Electron Microscope (SEM), Alicona Infinite Focus, Vicker’s Hardness Test, Raman spectroscopy, and Adhesion test. The corrosion and wear rate of the coatings were investigated using a Slurry Erosion tester and Salt Water spray, respectively. The results showed that the Ni-Go nanocomposite coating on a smooth surface roughness substrate achieved the highest microhardness, wear resistance, and corrosion resistance, with values of 468.8 HV, 0.182% weight loss, and 0.03% weight gain, respectively. This indicates that the specimen coated with a smooth surface roughness substrate provided better coating performance than the rough and medium surface roughness substrates.