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Physical and electrochemical characterisation of
electroless nickel coatings on carbon steelC. Kerr, D. Barker and F. Walsh
& f /z j/ca/ Sa'fMcej, [/m've rjz'rr. Mzc/za /'j Bw/dmg,
Abstract
Various electrolyte and deposit parameters were investigated to assess the performance of
electroless nickel coatings deposited from baths aged in the range 0-6 metal bath turnovers.
The properties studied included: measurement of internal stress, analysis of orthophosphiteconcentration in the plating solution and determination of phosphorus content in the deposit.
The effect of bath ageing on the hardness of the deposit in the as-plated condition, and after
heat treatment, was also examined. Changes in the deposit mainly appeared in the range of 3-
5 metal turnovers, suggesting that the life expectancy of these electroless nickel platingsolutions should not exceed 6 metal bath turnovers. The corrosion potential (E ) was
measured and the corrosion current density (i) of coated samples was determined by
extrapolation of polarisation vs. log current density (Tafel) plots in 0.125M P SOj. at 22°C.
Introduction and Literature Survey
Electroless nickel coatings on steel have properties such as excellent throwing
power and high hardness which have resulted in a wide range of industrialapplications, such as valves for fluid handling, hydraulic cylinders and
medical equipment [1-3]. The deposits exhibit good corrosion resistance in a
wide range of environments in the absence of defects present in the coating.However, nickel is more noble than ferrous substrates and severe corrosion
can result at the base of any through-pores due to the adverse condition of a
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
48 Surface Ireatment, Computer Methods and Experimental Measurements
large cathode area to a small anode area. Defects in the galvanic metal coating
can seriously reduce the design life and the range of service environments.
Porosity in electroless deposits has been attributed to improper pre-
treatment processes [4-8], surface roughness of the component being plated
[9], an adverse composition of the plating bath [10], design features of the
component and surface defects on the substrate prior to coating [11]. Traces
of soils remaining after cleaning will prevent the uniform autocatalytic
reduction of nickel from the solution and efficient cleaning of the ferrous
metal is vital. Rough surfaces tend to promote the development of pores due
to an increase in substrate surface area, entrapment of particles (such as
alumina from polishing pre-treatment processes) and the trapping of hydrogen
gas bubbles in the deep recesses on the surface [12-14].
A coating with a high internal stress is hazardous to cathodic deposits
as they can lead to crack formation and expose the substrate to the attacking
environment, or peel leading to poor adhesion of the coating. In the early
stages of deposit growth, the nature of the stress may have an important
bearing on the final levels of coating porosity found within the plated deposit.
A high compressive stress may not only help reduce porosity but also improve
deposit adhesion as electroless nickel coatings tend to have a relatively low
ductility. In the presence of surface defects or soil residues on te steel, an
electroless nickel coating can develop high tensile internal stresses, resultingin poor adhesion. When the component is subjected to applied loads, theinternal stresses within the deposit may have an important influence on the
time to failure such as in stress corrosion cracking and corrosion fatigue
conditions. The presence of a high tensile stress within the coating may bedetrimental to both deposit and substrate [15]; stressed areas are more likely tocorrode or to produce coating defects.
A phosphorus content of 11-13% is considered to result in a
compressive stressed deposit but lower phosphorus contents produce a tensile
internal stress. Baldwin and Such reported [16] that the cause and effect of
internal stress within electroless nickel deposits were a result of physical
changes in the electroless bath, e.g., pH, temperature and phosphite
concentration. Their results indicated a change from compressive to tensile
internal stress at pH 4.65; this was atributed to an increase in orthophosphiteconcentration as the bath aged. The results underline the importance ofcontrolling bath composition and operational parameters to optimise plating.
As part of a study to determine the factors affecting the porosity and
corrosion resistance of electroless nickel coatings, we have examined the
importance of operational parameters, particularly deposition time (and hence
deposit thickness and bath age) on the electrolyte composition, internal stress,
hardness, phosphorus content and corrosion stability of deposits using both
physical measurements and electrochemical techniques.
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
Surface Treatment. Computer Methods and Experimental Measurements 49
Experimental Details
10 x 2 cm samples were cut from 1.5 mm thick carbon (Pyrene) steel platesweighed and subjected to the following stringent sequence:
1) Alkaline soak cleaning (Duraprep 115-20 g drn ). The panels were
immersed for 5-10 minutes at a temperature of 55-60 C.
2) Rinsing (x 2) in deionised water at a temperature of 22°C, for 30-60 s.3) Pickling - HC1 (activation). The acid bath was a 25% vol HC1 (S.G.
1.18) and de-ionised water. Panels were immersed for 60 s at 22 C.4) Rinsing (x 2).
5) Repeating steps 1-4.
6) Duraposit 90 electroless nickel plating at 90-92°C, the plating rate forbeing approximately 12-14 (jm h~l.
The electroless nickel plated samples used in electrochemical tests were
covered with an acid resistant tape, exposing 1 cm? of metal. This enabled the
current measurements to be easily converted to current densities.Electrochemical measurements were carried out in 0.125M H SC at 22°C.
The cell and experimental arrangement for polarisation measurements
are described in more detail elsewhere [22]. A three-compartment glass cell
was used having a working electrode compartment volume of approximately
100 crrA The SCE reference electrode was connected to the cell via a luggin
capillary while the counter electrode (platinum foil, 3.4 cm?) was isolated
from the cell by means of a Nafion 324 (DuPont) cationic membrane. This
prevented any products generated at the counter electrode interfering with the
electrochemical measurements. A microcomputer-controlled EG & Gpotentiostat (model 273A) was used, with a scan rate of 1 mV s-l for Tafel(potential vs. log current density) plots.
The stress within an electroless nickel deposit was determined by theuse of a Brenner-Senderoff spiral contractometer [19]. This instrumentconsisted of a strip of stainless steel (2.54 x 30 x 0.15 cm thick) wound in the
shape of a helix (2.5 cm diameter). Its interior was coated with a lacquer thuspreventing the deposition of electroless nickel inside of the helix. The helix
was fixed at one end of the spiral contractometer while the other end was free
to rotate, thereby, moving a pointer on the dial. From the direction of rotation
(clockwise for tensile and anti-clockwise for compressive stress) and amount
of deflection recorded, the type and extent of internal stress was then
measured. The spirals were chemically treated prior to electroless nickelplating (with times and conditions as for the mild steel pre-treatment):1. Alkaline soak cleaning, (Duraprep 115).2. Rinsing (x 2) in deionised water.
3. Pickling, (hydrochloric acid).
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
50 Surface Treatment. Computer Methods ana bxpenmental Measurements
4. Rinsing (x 2) in deionised water.
5. Woods Nickel strike (nickel chloride 240 g , HC1 (S.G. 1.18) 86 crn^
made up to 1 dnr^ with deionised water). The spiral was immersed for
1-2 minutes at a temperature of 22°C and was electroplated at acurrent density of 5 A dm--.
6. Rinsing (deionised water), washing, (alcohol), drying and weighing.
7. Electroless nickel deposition, (Duraposit 90).
8. Rinsing (deionised water), washed, (alcohol), dried and reweighed.
The procedure adopted for the analysis of the sodium orthophosphite
concentration followed the instructions in the manufacturer's data sheet for
Duraprep and Duraposit, which are trade names for chemicals supplied by
Shipley Europe Ltd.. The phosphorus content within electroless nickel
deposits was determined as follows. A sample of electroless nickel foil was
prepared by passivating the steel substrate in chromic acid (1100 g dm'3).
After through rinsing to remove any excess chromic acid, the passivated steelwas plated in various aged electroless nickel baths for 1 hour at 92°C. Once
plated, the nickel-phosphorus foil was stripped from the steel, dried and
weighed; phosphorus content was determined by ion chromatography.
The hardness of various aged electroless nickel deposits was
determined using a M41 Vickers microhardness instrument utilising a
diamond pyramid indenter. The samples were etched to distinguish the
electroless nickel deposit from the mild steel substrate using 1% nital (1%
nitric acid (S.G. 1.42) in ethanol). A 50-100 g load was used and an average
Knoop hardness for 10 measurements was taken. The area of interest wasviewed under low magnification (x 40) before the pyramid indenter was
placed over the deposit. This procedure was repeated for the samples heattreated at 400°C for 1 hour.
Results
The electrode potential of the sample was adjusted to a value 0.25 V more
negative than the open circuit value then the potential was scanned to a value0.25 V more positive than the open circuit. The 1 cm^ area of the sample
allowed current readings to be directly expressed as current density ()J A crrr ).
Figure 1 shows the E vs. log i plots for uncoated steel and various electroless
nickel deposits. The value of i or %od ^COT extrapolated from this figure, areshown in the inset graph of Figure 1 and in Table I.
The value of E^r becomes more noble as the deposit thicknessincreases which agrees with the corrosion potential vs. time behaviour seen
earlier. The value of corrosion current density decreases, however, from a
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
Surface Treatment, Computer Methods and Experimental Measurements 51
value of 55 pA crrr? (uncoated steel), to 8 pA cnr-for a pore-free, 24 pm
nickel deposit. Porous deposits of nickel on steel showed intermediate values.
00
-02
•£
I
- 1 u m deposit j-Sum deposit I- G u m deposit !- 12 u m deposit!- 18 pi m deposit I- 24 u m deposit j
- 6 - 5 ^ - 3
Log(i/mAcm^)
Figure 1: Cathodic Tafel plot of mild steel and various electrolessnickel deposits from in 0.125M P SO at 22 C.
The inset shows data obtained for a range of plated deposits.
Deposit thickness
/pm
24
18
12
6
3
1
0
Corrosion potential
Ecor vs. SCE/v
-0.205
-0.230
-0.388
-0.423
-0.425
-0.447
-0.539
Corrosion current
ICOF/pA cm"
7
5
9
30
30
30
61
density
2
Table I Tafel analysis of electroless nickel deposits of various thickness.
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
:>z Surface treatment. Computer Methods and Experimental Measurements
If two electrodes, one of pure iron and one of pure electroless nickel(i.e., a pore free deposit) are joined, the nickel electrode becomes the cathode
while the iron becomes the anode and corrodes. This can be analogous to the
cathodic protection of ferrous structures by sacrificial anodes such as
aluminium or zinc. In the electroless nickel-iron couple, the iron will have to
corrode at a rate greater than I^t to depress the potential of the electroless
nickel into the zone of immunity, i.e., Ep^ for nickel. This is illustratedschematically in Figure 2.
EvsSCE/ V-0.0-
-0.1-
-0.2-j
Eprot - L-0.3
-0.4
-0.5
(e)
(d)(c)
Ni/Ni
Log (I / A)
Figure 2:
-5 -4
A schematic, Evans diagram illustrating the cathodic protection
of the electroless nickel deposit. The corrosion potential, E p,
becomes more noble and the corrosion current density, i ofalls for thicker deposits.
(a) Uncoated steel substrate, (b) 3 jam electroless nickel deposit.
(c) 12 jam electroless nickel deposit, (d) 18 jam electroless nickel deposi
Below this value of Ep , the electroless nickel will be 100 % cathodic and
thereby protected. Pores within the electroless nickel deposit on the steel
substrate may be considered as sacrificial anode sites. If these sites aresufficiently large they can confer protection to the electroless coating. The
coverage of the steel by even a thin coating of electroless nickel, e.g., 2 |am,
will reduce the area of iron available to cathodically protect the electroless
nickel. This lowers the anodic current produced by iron dissolution and the
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
iicaimenu computer ivietnoas and hxpenmental Measurements 53
mixed potential of the iron-electroless nickel moves in a positive (i.e., more
noble) direction as illustrated in Figure 2. This mixed potential is in reality, the
value of E^r measured experimentally. Increasing the deposit thickness
further reduces the anodic area of the pore and the subsequent anodic currents;the mixed couple potential moves in a more noble direction.
The corrosion rates obtained form the Tafel experiments decreased
with increased deposit thickness. The value of corrosion potentials where the
current became zero were very slightly different to those from simple
immersion tests [22]. This is not surprising as these results were taken after 50
hours in the 0.125M sulphuric acid while in the Tafel experiments, the
potential was estimated after approximately 15 minutes. In addition, the
cathodic scan will possibly reduce oxide films which might be on the surface
of the nickel and/or the steel. This will also cause the potentials to be slightlydifferent between the two techniques.
Figure 3 shows the results of the stress measurements. Initially, the
fresh bath produces a compressive internal stress of 37-24 MPa at 0-1 metal
turnovers. The stress decreases with increased number of metal turnovers, and
after 3 turnovers, the stress becomes tensile. The value of this tensile stress
increases as the bath ages reaching a value of 241 MPa after 6 metal turnovers.
(/)CLif)$(%
40000
36000
30000
•<£<_ijj
20000
15000
10000
5000
0
-5000
-10000
', ' ' ' ' I • I ' 1 • 1 r- 1
—• — Ex pen mental j O- O- Manufacturer's guideline |
-= Compressive stress-*• = Tensile stress -O
- "~*mr ^/X x/
0'" /,''*— — •
- ,-_._-•/ ;
• — -* - o-
— ' ' 1 . 1 , I . . . , . , "2 3 4Number of metal tumo/ers
Figure 3: Variation of the internal stress in the electroless nickel deposit
with increased number of bath metal turnovers for a highphosphorus electroless nickel plating solution
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
54 Surface Treatment, Computer Methods and Experimental Measurements
This result is consistent with other workers [10] and the supplier's data for the
electroless nickel bath but in disagreement with the findings of Bleeks and
Brindisi [20] and Keene [21]. The high phosphorus electroless nickel system
investigated by Bleeks and Brindisi showed that the internal stress of the
deposits, measured by a gearless spiral contractometer, remained compressive
even after 6 metal turnovers. Work carried out by Keene also showed that the
internal stress within deposits plated from a high phosphorus electroless nickel
bath remained compressive up to 6 metal turnovers.
The plating rate vs. the number of bath metal turnovers is illustrated in
Figure 4. The plating rate remains fairly consistent until 4.5 metal turnovers
when the plating rate suddenly starts to fall. This lowering of the plating rate
coincides with higher values of tensile stress found after 4-5 metal turnovers.
150 —•— High phosphoruselectroiess nickel
14.5
14.0
fcS" 135
E 130<D
120
11.52 3 4
Number of metal turnovers
Figure 4: Plating rate of a high phosphorus electroless nickel solution
from baths aged by 0-6 metal turnovers.
Results of the analysis of the bath for orthophosphite concentration areshown in Figure 5 as a linear relationship between the concentration of the
orthophosphite ion and the number of bath metal turnovers. During electroless
nickel deposition, hypophosphite is oxidised to orthophosphite. As the bathages, the concentration of the orthophosphite in the plating solution must
increase. A comparison of Figure 5 with Figure 3 indicates that the high
levels of tensile stress maybe associated with orthophosphite concentrations inexcess of 125 g dm-3. This corresponds to a bath metal turnover of
approximately 4.5 at which point the plating rate begins to fall (see Figure 4).
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
Surface Treatment. Computer Methods and Experimental Measurements 55
Where;m = 34.19054 (sd 0.59652), c = 0.32112 (sd 1.88399)R = 0.9987, N = 10, SD = 3.51515 & P = 95312 x
3 4NaofMe&tLmM-rs
Figure 5: Variation of the sodium orthophosphite concentration with
increased number of metal turnovers of a high phosphorus
electroless nickel bath.
The phosphorus content of the deposit was found to be in the range of
11.3-13.3% wt (c.f. 11-13% wt, which is the expected range quoted by the
manufacturer). This value was maintained throughout irrespective of the
number of metal turnovers. The amount of phosphorus incorporated withinthe deposit, however, gradually increased with the number of metal turnovers.
This is illustrated in the plot of weight % phosphorus vs. number of metal
turnovers (Figure 6). This may not be directly related to the age of the
solution, but as a result of the plating rate. Factors which alter the plating rate
also tend to effect the amount of phosphorus incorporated within the deposit.
A increase in the deposition rate coincides with a fall in the phosphoruscontent although the reason for this is still uncertain. As shown in Figure 4,
the plating rate falls with increased orthophosphite levels and this may explain
the gradual increase of phosphorus observed in the deposits plated from bathswith a higher number of metal turnovers.
Figure 7 shows that the values of Knoop hardness, H%, found in the as-
plated condition (H^ 550-600) remain consistent for a 12-14 jam deposit plated
from various electroless nickel solutions (0-6 metal bath turnovers). Heattreated coatings show a marked increase in hardness compared to the as plated
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
56 Surface Treatment, Computer Methods and bxpenmental Measurements
120
11.5
11.0
105O0_
100
9.0
I—wt%P
1 2 3 4
Number of metal turnovers
Figure 6: Phosphorus content of an electroless nickel deposit
plated from baths aged in the range 0-6 metal turnovers.
Knoop hardness /H %
1000
900
800
TO)
600
500
400
qm
1 ' I ' 1 ' 1 ' 1 ' I ' I
"*~~" \ -""' ~~~~— — -.- _• .-
—O— Knoop hardness (H ) as plated High phosphorus electroless nickel (EN)— •— Knoop hardness (H ) Pyrene steel— •— Knoop hardness (H ) High phosphorus EN heat treated @ 400 °C for 1 hr— O— Knoop hardness (H ) Pyrene steel heat treated @ 400 °C for 1 hr
-
U " \^ _ G— — __ n-—" -^" • .r-i ~
^^Q Q -O— Q Q Q O
™ • • • -•— — _ ^ ^ ** ~## ^ w ^
1 , 1 , 1 , 1 , 1 , 1 . 12 3 4
Number of metal turnovers
Figure 7: Knoop hardness measurements taken from samples plated
from solutions aged by 0-6 metal turnovers before and after
heat treatment (1 hour at 400°C).
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
sunace ireaimem, computer ivietnoas ana experimental Measurements :> /
condition and there is no noticeable difference in H% value (H^ 900-1000)
between deposits plated from 0-6 metal turnovers. Hardness properties are,
therefore, not dependent on factors influencing the ageing process of
electroless solutions. Hardness is attributed to the phosphorus content of thedeposit, and this present work has illustrated that the phosphorus content
within the coating remains fairly constant, whether it is plated from a fresh
bath or an aged solution. With the levels of deposit phosphorus remaining
consistent irrespective of bath age the level of hardness of these deposits was
also found to follow the same trend.
The present research has shown the characterisation of electroless
nickel deposits from acid baths alters as the bath ages. The ageing of the bath
is directly related to metal turnover additions. Between 4 and 5 metal
turnovers, this change is most noticeable as can clearly be seen in Figure 8
with the plating rate decreasing from 14 to 9.5 jam hr*. This decline in plating
rate can be attributed to the build-up in concentration of sodium
orthophosphite, a by-product of the oxidation process. The level of sodium
orthophosphite builds up on a linear scale as the bath ages rising to a
maximum level of 190 g dm-3 after 6 metal turnovers, when the solution has
reached the end of its useful working life.
The internal stress within the deposit becomes highly tensile between
metal turnovers 4 and 5, and this demonstrated in Figure 8.
200
180
160
140
120
100
80
60
40-
3D-
0
Pfetingrate mh^-T 16
—<*—- R^Jngtime/mn —a—9ress/MF£• Crthcphasphte core. —A— wt % P
--15
E 140--
^ 80-
iiterrcl stress /IVPar120
9.02 3NuTter cf metal turcMers
Figure 8: Various physical parameters , number of metal turnovers.
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
58 Surface Treatment, Computer Methods and Experimental Measurements
The internal stress measured within the deposit is thought to be associated
with the amount of phosphorus included in the coating. There are conflicting
reports in the literature on the role of phosphorus. Results presented in this
paper closely mirror those reported by Riedel and his co-workers but are in
disagreement with those published by Bleeks and Brindisi [20] and by Keene
[21]. The latter work showed that, for high phosphorus alloys, the internal
stress remains compressive in deposits plated from solutions aged by 0-6
metal turnovers. Analysis of electroless nickel foils indicated that the ageing
process had little effect on the weight % phosphorus found with levels rising
slightly, with increased number of metal turnovers.
Conclusions
The use of electrochemical measurements in the detection of pores in
electroless deposits has been demonstrated to be an effective alternative to the
conventional corrosion or chemical tests. Tafel polarisation measurements
have been shown to be able to identify the presence of pores through the
coating to the underlying steel substrate. The shape of the corrosion current
density vs. coating thickness plots have a very similar resemblance to the
coating thickness vs. percentage porosity curves as shown in a previous study
using the sulphur dioxide corrosion test [4], Good agreement has beenobtained between these exposure tests and electrochemical measurements inpredicting the presence of pores with the widely employed sulphur dioxide
test. The electrochemical tests can give an estimation of the presence of pores
in a matter of hours compared with days for the sulphur dioxide test i.e., Tafel
analysis can be rapidly carried out, once the sample has been prepared.
The characterisation of electroless nickel deposits from acid baths is
dependent on the bath age, which is related to metal turnovers. Between 4 and
5 metal turnovers, this change is most noticeable, with the plating rate
decreasing from 14 to 9.5 jam h~*. This decline in plating rate can be attributed
to the build-up in concentration of orthophosphite. The level of orthophosphite
builds up linearly with time as the bath ages, rising to a maximum level of 190g dm-3 after 6 metal turnovers, when the solution has reached the end of its
useful working life.
The role of phosphorus, the part it plays on the internal stresses withinthe Ni-P deposit and the influence of operational parameters are not well
understood in the electroless nickel system and further work is required to
understand the interactions amongst: electrolyte composition, operatingconditions, the kinetics of depostiion and the physical properties of the deposit
Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533
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20. T.W. Bleeks and F. Brindisi, Jr., "The properties and characteristics ofelectroless nickel coatings applied to gas turbine engine components",Presented at the Gas Turbine and Aeroengine Congress and Exposition -June 4-8, 1989, Toronto, Ontario, Canada. (ASME 89-GT-4).
21. R.H. Keene, "Application and control of electroless nickel processes atNorth West Airlines", Plating and Surface Finishing, Dec. 1988.
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Transactions on Engineering Sciences vol 17, © 1997 WIT Press, www.witpress.com, ISSN 1743-3533