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<p>Recently, heat exchangers serve as essential equipment for facilitating heat transfer and are widely applied in sectors, such as chemical, petroleum, electric power, and refrigeration. To enhance the corrosion resistance (Ref <i>R</i>c) of heat exchanger tube bundles, Ni-P-SiC composite coatings were fabricated on their surfaces through ultrasonic electrodeposition. The prepared coatings were characterized via scanning electron microscopy, neutral salt spray testing, and other analytical methods to assess the effects of deposition parameters on surface morphology and corrosion performance. Ultrasonic power, current density, temperature, and SiC content were selected as the key variables, with corrosion loss of the coating serving as the response indicator. Response surface methodology (RSM) was utilized through JMP (John’s Macintosh Program) software to optimize the process parameters and identify optimal combinations for the coatings. The results demonstrated that these factors significantly influenced the surface morphology and the <i>R</i>c value of the synthesized Ni-P-SiC coatings. The optimal process parameters were determined as follows: ultrasonic power of 202.74 W, current density of 8.76&#xa0;A/dm<sup>2</sup>, temperature of 62.41&#xa0;°C, and SiC concentration of 6.65 g/L. Based on these optimized conditions, several Ni-P-SiC coatings were prepared. Experimental results revealed that the actual average corrosion loss was 7.63 mg, closely aligning with the predicted value of 7.46 mg. The relative error was only 2.23%, verifying the high accuracy of the established mathematical model. Performance analysis demonstrated that the coatings produced under the optimized parameters demonstrated significantly improved surface quality and overall properties. These findings offer a valuable theoretical foundation and technical guidance for heat exchanger tube bundle surface protection technologies, holding significant scientific importance and practical value in advancing the efficient, long-lasting operation of industrial equipment.</p>

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Study on Ultrasonic Electrodeposition of Ni-P-SiC Coatings on Heat Exchanger Tube Bundle Surface

  • 期刊论文

  • 发表日期：

    2025年10月30日

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  • Xing Huang,
  • Haoyu Wang

摘要

Recently, heat exchangers serve as essential equipment for facilitating heat transfer and are widely applied in sectors, such as chemical, petroleum, electric power, and refrigeration. To enhance the corrosion resistance (Ref Rc) of heat exchanger tube bundles, Ni-P-SiC composite coatings were fabricated on their surfaces through ultrasonic electrodeposition. The prepared coatings were characterized via scanning electron microscopy, neutral salt spray testing, and other analytical methods to assess the effects of deposition parameters on surface morphology and corrosion performance. Ultrasonic power, current density, temperature, and SiC content were selected as the key variables, with corrosion loss of the coating serving as the response indicator. Response surface methodology (RSM) was utilized through JMP (John’s Macintosh Program) software to optimize the process parameters and identify optimal combinations for the coatings. The results demonstrated that these factors significantly influenced the surface morphology and the Rc value of the synthesized Ni-P-SiC coatings. The optimal process parameters were determined as follows: ultrasonic power of 202.74 W, current density of 8.76 A/dm2, temperature of 62.41 °C, and SiC concentration of 6.65 g/L. Based on these optimized conditions, several Ni-P-SiC coatings were prepared. Experimental results revealed that the actual average corrosion loss was 7.63 mg, closely aligning with the predicted value of 7.46 mg. The relative error was only 2.23%, verifying the high accuracy of the established mathematical model. Performance analysis demonstrated that the coatings produced under the optimized parameters demonstrated significantly improved surface quality and overall properties. These findings offer a valuable theoretical foundation and technical guidance for heat exchanger tube bundle surface protection technologies, holding significant scientific importance and practical value in advancing the efficient, long-lasting operation of industrial equipment.