Influence of particle size on the microstructure, hardness and corrosion resistance of electroless Ni–P–Al2O3 composite coatings

High phosphorus electroless nickel bath has been used to prepare composite coatings containing alumina powders (50 nm, 0.3 μm and 1.0 μm). Deposits were characterized for its structure, morphology and hardness. Incorporation of particle has a marginal influence on the composition. More amount of particle incorporation and uniform distribution was found in composite coatings obtained with 1.0-μm (C3) alumina particles compared to 50-nm (C1) and 0.3-μm (C2) alumina particles. XRD results showed a broad peak of nickel and low intensity alumina peaks present in C3 composite coating in as-plated condition. A marginal improvement in hardness was noticed in as-plated composite coatings. A 15% increase in microhardness was observed in the heat-treated (400 °C for 1 h) composite coatings. Potentiodynamic polarization measurements made on these deposits in 3.5% sodium chloride solution showed that uniform corrosion occurred in C1 and C2 composite coatings whereas localized corrosion was observed in C3 composite coating.