Synthesis of Ni–Co–ZrO2 nanocomposites doped with ceria particles via electrodeposition as highly protective coating

A novel Ni–Co–ZrO2 nanocomposites doped with ceria particles has been synthesized by pulse electrodeposition as highly protective coating. The effect of current density and duty cycle on its structure and properties were evaluated. The composite coatings are compact with hill-valley like structure. The average roughness (Sa) was about 73–98 nm and the duty cycle of 70% benefits low roughness and fine-grained structure. The crystallite size of these coatings is 17–20 nm. The nanocrystalline coating exhibits the preferred orientation of Ni (111) texture. AFM and XPS were utilized to analyze the surface properties. EIS results indicated that the electrodeposition parameters greatly affect the corrosion behavior of the nanocomposites. The electrochemical behavior varied with immersing time. Duty cycle of 30%, current density of 2 A dm−2 were the appropriate parameters for the best corrosion and wear resistance and optimal long-term electrochemical stability in 3.5 wt% NaCl corrosive solution. This coating shows good potential for engineering application in aggressive medium. •Ni–Co–ZrO2–CeO2 nanocomposites has been synthesized by pulse electrodeposition as protective coating.•Effects of current density and duty cycle on structure and properties were investigated•Surface topography, roughness, properties and formation mechanism were analyzed.•Corrosion and wear resistance of Ni–Co matrix was improved by incorporation ZrO2 and CeO2 nanoparticles.•2 A dm−2 and 30% was suitable parameters for best corrosion resistance and long-term electrochemical stability.