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<p>This work reports the controllable electrodeposition of dense, adherent metallic chromium coatings from a low-cost, environmentally benign NaCl-CaCl<sub>2</sub>-CrCl<sub>2</sub> molten salt. The influence of key process parameters, including cathodic current density (10-70&#xa0;mA&#xa0;cm<sup>−2</sup>), temperature (620-720&#xa0;°C), time (3-60&#xa0;min), and substrate material (304 stainless steel, Ni, W, Mo), on the microstructure and growth behavior of the coatings was systematically examined. Optimal conditions were identified at 620&#xa0;°C and 30&#xa0;mA&#xa0;cm<sup>−2</sup>, resulting in smooth, uniform, and fully dense chromium coatings. Under these optimal conditions, the coatings exhibited a strong (200) preferred orientation, with an average growth rate of 0.65&#xa0;μm&#xa0;min<sup>−1</sup> and a cathode current efficiency of approximately 96%. In contrast, higher current densities or elevated temperatures led to the formation of nodular structures and grain coarsening, attributable to mass transport limitations and enhanced adatom mobility, respectively. The process demonstrated excellent versatility, producing dense coatings on all tested substrates. Crucially, a strong metallurgical bond was formed via interfacial inter-diffusion. This study establishes a clear process-structure relationship, affirming this molten salt method as a promising environmentally friendly alternative to traditional chromium plating.</p>

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Controllable Fabrication of Metallic Chromium Coatings by Electrodeposition in NaCl-CaCl2-CrCl2 Molten Salt

  • 期刊论文

  • 发表日期：

    2026年5月3日

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  • Chuntao Ge,
  • Liwen Sun,
  • Qian Kou,
  • Jun Zhang,
  • Saijun Xiao

摘要

This work reports the controllable electrodeposition of dense, adherent metallic chromium coatings from a low-cost, environmentally benign NaCl-CaCl2-CrCl2 molten salt. The influence of key process parameters, including cathodic current density (10-70 mA cm−2), temperature (620-720 °C), time (3-60 min), and substrate material (304 stainless steel, Ni, W, Mo), on the microstructure and growth behavior of the coatings was systematically examined. Optimal conditions were identified at 620 °C and 30 mA cm−2, resulting in smooth, uniform, and fully dense chromium coatings. Under these optimal conditions, the coatings exhibited a strong (200) preferred orientation, with an average growth rate of 0.65 μm min−1 and a cathode current efficiency of approximately 96%. In contrast, higher current densities or elevated temperatures led to the formation of nodular structures and grain coarsening, attributable to mass transport limitations and enhanced adatom mobility, respectively. The process demonstrated excellent versatility, producing dense coatings on all tested substrates. Crucially, a strong metallurgical bond was formed via interfacial inter-diffusion. This study establishes a clear process-structure relationship, affirming this molten salt method as a promising environmentally friendly alternative to traditional chromium plating.