Effect of coating time and heat treatment on structures and corrosion characteristics of electroless Ni–P alloy deposits

Mild steel was electroless coated with nickel–phosphorus alloy from a bath containing sodium hypophosphite and glycin–citrate complexing agents. The effect of coating time on phosphorus content, thickness, structure and hardness of the deposits were analyzed. Corrosion parameters such as current density, corrosion potential and corrosion rate were obtained from tafel polarization curves and immersion corrosion tests in aerated 3.5% NaCl solution. The X-ray diffraction (XRD) patterns, anodic polarization curves and scanning electron microscopy (SEM) of heat-treated specimens obtained in various coating times were also studied. The X-ray diffraction patterns showed that by changing the coating times, amorphous or crystalline structure could be obtained. The coatings containing 11.1–13.1% phosphorous were amorphous, and showed better corrosion resistance than microcrystalline structure. The heat-treated specimens obtained in different coating time had more hardness and corrosion resistance than unheated samples. According to the polarization studies and scanning electron microscopy images, the heat-treated samples with 10.8 and 10.1% phosphorous show the intergranular corrosion, while the coatings with 11.7 and 12.2% of phosphorus have the least corrosion rate. Immersion corrosion test data at the 4-month interval had good agreement with electrochemical polarization results.