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Electroformed Nanocrystalline Coatings: An Advanced Alternative to Hard Chrome Electroplating

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Final rept. 13 Jun 2000-13Jun 2003

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This report is prepared as the final report for SERDP Project PP-1152, Electroformed Nanocrystalline Coatings An Advanced Alternative to Hard Chrome Electroplating. The purpose of the project is to develop an environmentally benign, cost-effective replacement for hard chrome to be applied to non-line-of-sight-surfaces. The project incorporates electrodeposited nanocrystalline technology that produces materials with comparable performance to hard chrome. The report is organized into activities associated with Phases II and III of the project. Phase II optimizes the coating process and Phase III extends the process to complex internal diameter shapes. For each activity, the developmental process followed and experimental results obtained are presented. A summary of the process developed and current performance of the material as compared to hard chrome is presented. In Phase I, three different alloy coatings were synthesized on a laboratory scale utilizing a designed experimental approach on the basis of previously developed intellectual property . Binary alloys, Co-P and Co-Mo, were produced along with the ternary alloy, Co-Fe-P. These alloys were evaluated for grain size, hardness, coating thickness and thermal stability. Phase I also included effort to establish baseline emission, chemical waste production and process cost data. In Phase II, a nanocrystalline cobalt-phosphorus alloy and associated process has been established, studied and optimized. Performance tests have been conducted on uncoated and coated samples as well as reference materials to establish properties and performance. As part of Phase III, the nanocrystalline cobalt-phosphorus alloy coating was applied to internal diameter surfaces. Anode selection and plating parameters were selected and tested on mock-ups designed to simulate the typical internal diameter surfaces encountered in DOD applications.

Subject Categories:

  • Coatings, Colorants and Finishes
  • Fabrication Metallurgy

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