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<p>Nickel coatings were printed by meniscus-confined electrochemical additive manufacturing method at different electrolyte temperatures and potentials. The microstructure and morphology of the surface and the cross section of the as-printed coatings were characterized using scanning electron microscopy and optical microscopy. The chemical composition of the coating was determined by energy-dispersive x-ray spectroscopy. The residual stress, grain orientation and phase identification of the coatings were determined by x-ray diffraction. The electrochemical corrosion resistance of the coatings was evaluated by dynamic polarization. The results show that the surface of nickel coating printed at 60&#xa0;°C has a distinct pyramidal-shape structure, while the surface of nickel coating produced at 25&#xa0;°C has a spherical-shape structure. Furthermore, as the printed potential increases, the preferred orientation of the coating changes from (111) crystal plane (2&#xa0;V potential) to (111) + (200) crystal planes (2.5&#xa0;V potential), then evolved into (200) crystal plane (3&#xa0;V potential) and finally to (220) crystal plane (4&#xa0;V potential), while the coating printed at 60&#xa0;°C has random orientation. As the applied potential increased, the surface roughness of the coatings decreased. Furthermore, the average residual stress of coatings printed at 25&#xa0;°C shows a tensile stress. The thin coating printed at 60&#xa0;°C × 2.5&#xa0;V exhibited good corrosion resistance due to the effects of the compactness and the random orientation.</p>

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Characterizations, Residual Stress and Corrosion Resistance of Nickel Coatings Printed by Meniscus-Confined Electrochemical Additive Manufacturing Process

  • 期刊论文

  • 发表日期：

    2025年6月9日

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  • Xin Li,
  • Guang He,
  • Wangping Wu,
  • Yongcheng Geng,
  • Meng Wu

摘要

Nickel coatings were printed by meniscus-confined electrochemical additive manufacturing method at different electrolyte temperatures and potentials. The microstructure and morphology of the surface and the cross section of the as-printed coatings were characterized using scanning electron microscopy and optical microscopy. The chemical composition of the coating was determined by energy-dispersive x-ray spectroscopy. The residual stress, grain orientation and phase identification of the coatings were determined by x-ray diffraction. The electrochemical corrosion resistance of the coatings was evaluated by dynamic polarization. The results show that the surface of nickel coating printed at 60 °C has a distinct pyramidal-shape structure, while the surface of nickel coating produced at 25 °C has a spherical-shape structure. Furthermore, as the printed potential increases, the preferred orientation of the coating changes from (111) crystal plane (2 V potential) to (111) + (200) crystal planes (2.5 V potential), then evolved into (200) crystal plane (3 V potential) and finally to (220) crystal plane (4 V potential), while the coating printed at 60 °C has random orientation. As the applied potential increased, the surface roughness of the coatings decreased. Furthermore, the average residual stress of coatings printed at 25 °C shows a tensile stress. The thin coating printed at 60 °C × 2.5 V exhibited good corrosion resistance due to the effects of the compactness and the random orientation.