Comparative Corrosion Behavior of Electroless Nickel Coatings on Bearing Steel in Acidic and Alkaline Environments

Abstract Electroless nickel coatings are valued in industrial applications for their excellent wear resistance, hardness, and corrosion protection. Unlike electroplating, this method requires no external power source, allowing uniform coverage even on complex shapes. It also offers strong adhesion, reduced friction, and enhanced durability, making it suitable for harsh environments such as those found in food and beverage processing. Equipment in this industry faces challenges from abrasion, thermal cycling, and exposure to acidic or alkaline cleaning agents, which can degrade the materials and compromise product quality. While the corrosion and wear resistance of electroless nickel coatings is well documented, limited data exists on these coatings’ stability in cleaning solutions. This study evaluated coatings with varying phosphorus content using electrochemical testing, including potentiodynamic polarization and electrochemical impedance spectroscopy, under acidic and alkaline conditions. Surface properties such as nanohardness, adhesion, composition, and thickness were also examined. Results indicated strong corrosion resistance in alkaline environments for the low-phosphorus coating. In acidic media, the high-phosphorus coating outperformed low-and medium-phosphorus variants. These findings offer important insights into the chemical performance of electroless nickel coatings and inform their potential and limitations in demanding industrial settings.

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