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Study of the formation of alkaline electroless Ni-P coating on magnesium and AZ31B
magnesium alloy
A.A. Zuleta1,*, E. Correa2, J.G. Castaño3, F. Echeverría3, A. Baron-Wiechec4
P. Skeldon5 and G.E Thompson5
1Grupo de Investigación de Estudios en Diseño - GED, Facultad de Diseño Industrial,
Universidad Pontificia Bolivariana, Sede Medellín, Circular 1 Nº 70-01, Medellín, Colombia
2Grupo de Investigación Materiales con Impacto – MAT&MPAC, Facultad de Ingenierías,
Universidad de Medellín, Carrera 87 N° 30 – 65, Medellín, Colombia
3Centro de Investigación, Innovación y Desarrollo de Materiales – CIDEMAT, Universidad
de Antioquia, Carrera 53 N◦61-30, Medellín, Colombia
4UK Atomic Energy Authority, Culham Centre for Fusion Energy, OX11 3DB, Abingdon,
UK
5Corrosion and Protection Centre, School of Materials, The University of Manchester, Oxford
Rd., Manchester M13 9PL, UK
Abstract
In this work, alkaline electroless Ni-P coatings were directly formed on commercial purity
magnesium and AZ31B magnesium alloy substrates using a process that avoided the use of
Cr(VI) compounds. The study focused on two aspects of coating formation: (i) the effect of
the substrate roughness on the kinetics of the electroless Ni-P deposition process on
magnesium; (ii) the morphological and chemical evolution of the coating on both magnesium
*corresponding authorTel.: +57 4 448 83 88 Ext. 13642Fax : +57 4 448 83 88 E-mail: [email protected]
1
and the AZ31B alloy. For these purposes, gravimetric measurements, scanning electron
microscopy (SEM), X-ray diffraction (XRD), Rutherford backscattering spectrometry (RBS)
and open-circuit potential (OCP) measurements were employed. It is shown that a relatively
rough substrate promotes the rapid formation of the Ni-P coating on the substrate surface in
comparison with smoother substrates. Furthermore, the presence of fluoride ions derived from
the NH4HF2 reagent in the electroless Ni-P plating bath leads to formation of MgF2 a few
seconds after immersion in the bath; the MgF2. Subsequently, crystals of NaMgF3, with a
cubic morphology, are developed, which later become embedded in the Ni-P matrix. The
presence of fluorine species passivates the substrate during coating formation and hence
restricts the decomposition of the electroless Ni-P plating bath, which can occur due to release
of Mg2+ ions. Finally, according to gravimetric measurements, SEM and XRD, the plating
process is initially faster on magnesium than on the alloy.
Keywords: Magnesium, electroless coatings, surface morphology, coatings grown.
2
1. Introduction
In the last few years, the automotive, aerospace and electronic products industries, among
others, have triggered renewed interest in magnesium alloys as structural materials due to
properties such as low density (1.74 g/cm3), high specific strength and stiffness,
electromagnetic shielding capacity, excellent machinability and good castability [1,2].
However, the range of applications has been limited by poor wear and corrosion resistance
[1,3,4]. For this reason, surface tratments are needed in order to improve the surface
properties and thereby extend the use of magnesium and its alloys. Various processes, such as
electrodepostion [5–7], electroless coating [8–12], conversion coating [13–15],
microarcoxidation [16,17], gas-phase deposition [18,19], surface laser modification [20], and
the combination of two or more of the mentioned approaches, have been used to improve the
surface performance of the alloys; among these, electroless Ni-P plating offers the possibility
of generating uniform, crack-free, and well-adhered coatings, without the need of an external
power source [21,22].
It is well known that magnesium and its alloys are highly susceptible to corrosion during the
growth of electroless coatings [10,23], which are commonly formed in slightly acidic baths at
temperatures around 80 °C. Therefore, it is common practice to apply a pre-treatment to the
alloys before the immersion in the electroless Ni-P plating bath to avoid the corrosion during
the deposition process. One of the most common pre-treatments of the alloys involves acid
attack using a Cr(VI) containing solution [5,7,13,14] followed by passivation in a HF solution
[24] in order to form a protective film, which allows the deposition of the electroless Ni-P
coating without the corrosion of the substrate. However, it is important to reduce the use of
carcinogenic reagents, such as a hexavalent chromium, and it is desirable that hydrofluoric
acid be replaced by a less hazardous and lower volatility solution.
3
In this work, a new alkaline electroless Ni-P coating was deposited on the magnesium and
AZ31B magnesium alloy, using an optimized bath composition that provides enhanced
corrosion resistance. The selected process avoids the use of Cr(VI) species or hydrofluoric
acid, as demonstrated in our previous works [8,10]. The bath contains NH4HF2 as a source of
fluoride ions that enables passivation of the substrate. Furthermore, the reaction between
magnesium and fluoride ions in the bath leads to formation of fluorinated reaction products in
the coating [25,26]. However, little attention has been paid to the study of such species. Liu et
al. studied [26] the physical characteristics and microstructure of the fluoride film formed
during activation, finding the presence of inclusion-like products near the coating base,
although these were not examined in detail. Furthermore, Lui and Gao [25], who investigated
the electroless nickel plating on several magnesium alloys, observed the presence of “three-
dimensional crystallites” using scanning electron microscopy. Similarly, Qin et al. [27]
identified cubic crystals in the initial stages of formation of a Ni−P coating.
They are many publications that describe the optimization of electroless coating processes, the
coating properties and the effects of heat treatments on the coatings. However, the literature
on the initiation and growth of coatings on magnesium alloys is comparatively limited. In
addition, it is well known that the surface condition of the substrate has an important role on
both the plating process and the coating properties [28–31]. However, little importance has
been given to the study of the effect of surface finish on the Ni-P deposition process on
magnesium and magnesium alloys.
The aim of this work is to study the initiation and growth of electroless Ni-P coatings directly
on magnesium and AZ31B magnesium alloy substrates using an alkaline electroless Ni-P
plating bath, with a Cr(VI)-free substrate pre-treatment. The morphological and chemical
evolution of the coating during the plating process was studied, with a particular interest in
4
the development of fluorinated reaction products. In addition, an evaluation of the effect of
substrate roughness on the deposition process was assessed.
2. Experimental details
2.1 Specimen preparation
The study of the effect of surface roughness on the deposition process was made on
magnesium substrates only in order to avoid the possible effect of alloying elements on the
process. Specimens of commercial purity magnesium (99.9%), with dimensions of 10 x 10 x
2 mm, were ground with SiC paper of different grit sizes (#120, #600 or #1200). They were
then cleaned with ethanol, followed by removal of surface impurities left by the grinding
process, in an alkaline cleaning solution of 37 g/L NaOH and 10 g/L Na3PO4 for 600 s at 60
oC, with final rinsing in deionized water and drying in a hot air stream. The average roughness
(Ra) of the substrates was assessed on selected specimens by profilometry using a Veeco 3D
ContourGT optical surface profiler. The area of analysis was ~ 90 × ~ 70 μm. Specimens were
illuminated through a 2.5x objective. The remaining specimens were immersed immediately
in 50 cm3 of electroless Ni-P plating solution in order to form the coating on freshly ground
surfaces. The electroless Ni-P plating solution was contained in a polypropylene beaker
located in a thermostatically controlled bath. Two specimens were immersed simultaneously
for each test condition. In order to check the reproducibility of the coating process, tests were
performed in triplicate, using a fresh electroless Ni-P plating bath for each test. After the
immersion in the electroless Ni-P plating solution, the specimens were rinsed with deionized
water and dried in a warm air stream. The composition of the electroless Ni-P plating bath and
the plating conditions are given in Table 1. Additional details of the optimization of the
formulation of the electroless solution can be found elsewhere [10].
5
Table 1. Chemical composition and operating conditions of the electroless Ni-P plating bath.
Bath composition
Name Formula Concentration
Nickel sulphate hexahydrate NiSO4.6H2O 21.2 g/L
Sodium hypophosphite monohydrate NaH2PO2. H2O 24.2 g/L
Lactic acid C3H6O3 26.5 mL/L
Propionic acid C3H6O2 2.2 mL/L
Succinic acid C4H6O4 12.0 g/L
Ammonium hydrogen bifluoride NH4HF2 13..3 g/L
Operating conditions
pH* 10.5 ± 0.1
Temperature 80 oC ± 1 °C
Time 1800 s
*Adjusted with the addition of ammonium hydroxide (NH4OH)
The development of the electroless Ni-P coatings at different times of immersion in the
electroless Ni-P plating solution was examined on commercial purity magnesium (99.9%) and
AZ31B magnesium alloy (Al 2.9 %, Zn 0.82 %, Mn 0.34 % bal. Mg (wt.%)). Specimens of
the respective materials, with dimensions of 10 x 10 x 2 mm, were ground to a #100 grit SiC
finish and then grit-blasted for 5 min using a micro-grit-blasting apparatus, RENFERT- basic
classic 2945-4025, containing alumina grains (150 m), with a pressure of 60 psi, before
applying the pre-treatment described above. The coating deposition on the grit-blasted
specimens was performed as described previously, but with removal of specimens from the
electroless Ni-P plating bath after immersion for 15, 60, 120, 300, 600, 1200 and 1800 s.
6
2.2 Coating characterization
The kinetics of the coating deposition in the alkaline electroless Ni-P plating solution were
determined gravimetrically using a Metter Toledo AB 204 analytical balance. Before the
immersion, the specimens were measured and weighed. After immersion, the specimens were
extracted from the electroless Ni-P plating bath, rinsed with deionized water and dried in a
warm air stream, and then weighed again in order to calculate the weight change per unit
surface area for the corresponding surface condition. Fresh specimens and electroless Ni-P
plating solutions were used for each treatment time. Experiments were conducted in triplicate,
with the average values of the individual measurements presented in the results.
Morphological and microchemical examinations of the coatings were carried out by scanning
electron microscopy (SEM) using Carl Zeiss AG - EVO® 50 and ZEISS Ultra 55 scanning
electron microscopes (the latter for high-resolution images), both equipped with energy
dispersive X-ray (EDX) spectroscopy (OXFORD INCAPentaFET-x3). Cross-sections of
coatings were prepared metallographically, with polishing down to a 0.3 μm alumina finish;
no chemical etching was used. The coating structure was studied by X-ray diffraction (XRD)
using an X’Pert APD X-ray diffractometer with Cu Kα radiation. The data were recorded over
the 2θ range of 15–95o, with a step size of 0.05o and a step interval of 10 s.
The grit-blasted magnesium and AZ31B substrates after immersion in the alkaline cleaning
solution were analysed by Rutherford backscattering spectroscopy (RBS) using the Van de
Graaff accelerator of the Institut des NanoSciences de Paris. The area of analysis was ∼ 1
mm2. RBS was carried out using 1.75 MeV He+ ions, with the ion beam at normal incidence
to the specimen surface and with a scattering angle of 165°. The data were interpreted using
the RUMP program [32].
7
Finally, open circuit potential (OCP) measurements during the deposition process were
recorded as a function of time in a two-electrode Pyrex cell using an μAutolab Type III
electrochemical workstation. Either pure magnesium or AZ31B alloy was used as the working
electrode, with a saturated calomel electrode (SCE) as the reference electrode. The
measurements were repeated three times for both substrates; a typical example of the
measurements is shown in the results section.
3. Results and discussion
3.1 Effect of the substrate roughness on the formation of Ni-P coatings on magnesium
The surface roughness (Ra) values of magnesium specimens with either ground or grit-blasted
surfaces prior to immersion in the electroless Ni-P plating bath are listed in Table 2, together
with the weight gains following formation of electroless coatings for 1800 s. The mass gain of
the grit-blasted surface, which had the highest Ra of 2.1 μm, was 6.5, 22.3 and 52.2 times
higher than that of the surfaces ground to # 100, # 600 and # 1200 grit SiC, which had
progressively reducing Ra values of 1.33, 0.62 and 0.30 μm respectively.
Table 2. Surface condition and initial roughness of magnesium and mass gain after subsequent immersion in the
electroless Ni-P plating bath for 1800 s.
Surface condition Ra (µm) Mass change (mg/cm2)
Blasted with Al2O3 (150 µm) 2.10 ± 0.22 4.70 ± 0.42
# 120 SiC grit 1.33 ± 0.04 0.73 ± 0.09
# 600 SiC grit 0.62 ± 0.10 0.21 ± 0.04
# 1200 SiC grit 0.30 ± 0.01 0.09 ± 0.01
Figure 1 shows optical images of the magnesium substrates with the different Ra values before
and after immersion in the electroless Ni-P plating bath. The alumina blasted surface was
8
uniformly covered by the Ni-P coating. In contrast, the ground substrates exhibited dark and
light regions, labelled “1” and “2”, respectively, due to non-uniform coating coverage on the
surfaces of reduced roughness. A similar finding was made by Vitry et al. [33] for steel
substrates.
Figure 1. Optical images of magnesium with different surface finishes before and after immersion for 1800 s in
the alkaline electroless Ni-P plating bath.
A closer view of the specimens by SEM (Figure 2) revealed that the deposit formed on the
grit-blasted surface was of uniform appearance across the magnesium surface, consisting of
fine nodules, with a cauliflower-like surface morphology, which is typical of an electroless
nickel coating. In contrast, the ground surfaces showed distinct regions where either nodular
or cubic morphologies dominated.
9
Figure 2. Scanning electron micrographs (secondary electrons) of the magnesium surfaces with varying
roughness after immersion in the alkaline Ni-P plating bath for 1800 s. The top and bottom rows present details
of the dark and light regions respectively that are evident in the optical images of Figure 1.
According to the EDX analysis the nodules on the surface ground to a # 1200 SiC finish
(Figure 3 (a)) contained Ni and P indicating that they consisted of Ni-P coating material. For
the areas of predominantly cubic crystals (Figure 3 (b)), detection of Mg, Na, F and O
suggested the presence of a fluorinated compound and possibly magnesium oxide and/or
hydroxide. The crystals were of size up to about 2 μm,
10
Figure 3. Scanning electron micrographs (secondary electrons) and EDX spectra of the magnesium surface (#
1200 SiC grit finish) after immersion for 1800 s in the alkaline electroless Ni-P plating bath. (a) region 1 and (b)
region 2.
For the same specimen, XRD analysis (Figure 4) at the region dominated by cubic features
(region 2) revealed sharp peaks due to (i) the magnesium substrate, (ii) Mg(OH)2 (at 2Ɵ =
18.5o and 2Ɵ = 38o) and NaMgF3; the latter were products formed in the electroless Ni-P
plating bath. Furthermore, a broad peak centered at 2Ɵ = 45o was also present, corresponding
to Ni (111), which is attributed to either a nanocrystaline or amorphous phase. The results
support the analysis of the cubic crystals by EDX spectroscopy shown in Figure 3.
The relatively low rates of coating deposition on the less rough, ground surfaces expose
magnesium to the electroless Ni-P plating solution for a longer time than the rough surface
11
generated by alumina grit blasting, which, as will be shown later, is fully covered by the Ni-P
coating after a few minutes of immersion.
Figure 4. XRD pattern of the magnesium (#1200 SiC grit finish) after immersion for 1800 s in the alkaline
electroless Ni-P plating bath.
The prolonged contact of the magnesium with the electroless solution allows the Mg2+ ions to
react with the fluorine species in the bath [26,34] forming a passive layer that protects the
substrate against dissolution [35]. The fluorinated species form before the deposition of the
Ni-P coating , which correlates with the more negative values of the standard enthalpy of
formation of MgF2 (ΔHf = −1124 kJ/mol [36]) and NaMgF3 (ΔHf = −1716 kJ/mol [36]) in
comparison with Ni-P (ΔHf = -49.91 kJ/mol [37]). In addition, it is well known that ground
surfaces are more homogeneous when a finer abrasive paper is used, which reduces the
number of catalytic sites on the surface and hinders the nucleation of the coating [33].
Although the mechanism whereby the alumina grit-blasting ensures a complete covering of
the surface within the selected coating time is uncertain, it is well known that the amount of
energy stored in the magnesium surface by the grit-blasting is increased due to the severe
plastic deformation conferred by the impact of the Al2O3 particles with the substrate surface
and the associated generation of a high density of non-equilibrium defects (i.e vacancies,
dislocations) within the grains [9,38,39]. In addition, the alumina grit-blasted surface exhibits
a higher number of surface peaks and creates a large surface area [40], which results in a
12
higher chemical reactivity in comparison with a ground specimen [41]. Hence, for the grit-
blasted surface, the high chemical reactivity enables faster deposition of the Ni-P coating
material (see Table 2), such that the coating soon extends across the magnesium surface and
covers the fluorinated compounds formed in the early stages of the process.
3.2 Initiation and growth of alkaline Ni-P coatings on alumina grit-blasted magnesium
and AZ31B alloy substrates.
Figure 5 presents scanning electron micrographs that show the morphological changes of the
commercial purity magnesium surface, with prior alumina grit blasting, during the first 60 s of
the electroless Ni-P treatment. Before immersion, the substrate reveals a lamellar morphology
(Figure 5 (a)); this is typical of Mg(OH)2, which was identified to be present by XRD and
consistent with the presence of significant amounts of oxygen on the surface identified by the
results of RBS that are shown later. The Mg(OH)2 is formed during the cleaning process,
which was performed in a solution of pH ~ 10.5. After 15 s of immersion (Figure 5 (b)), the
surface was slightly corroded in the electroless Ni-P plating solution. A few roughly spherical
particles, of about 0.5 µm diameter, with a fine surface texture (indicated by arrows) were
distributed apparently randomly on the surface. After 30 s of immersion (Figure 5 (c)), two
different regions were evident, one with the typical morphology of Mg(OH)2 mainly
consisting of lamellae of a few nanometres in thickness that projected from the substrate
surface (labeled 2) and the other where the substrate appeared to have been passivated by
formation of a film with a nanometric texture (labelled 1). In the latter regions, the roughly
spherical particles observed at 15 s of immersion had increased in size to about 1 μm and
exhibited a pseudocubic shape. The presence of the different regions suggests a reaction had
occurred similar to that observed by Bradford et al. [42] and Turhan [43], who found that the
MgF2 was formed from Mg(OH)2 in solutions containing fluorides. The reaction involved
either the dissolution of Mg(OH)2 and reaction of the dissolved Mg2+ ions and F-ions or the
replacement or exchange of the hydroxyl ions by fluoride ions, resulting in the formation 13
MgF2. The Mg(OH)2 can be transformed during the coating formation due to an decrease in the
local pH on the magnesium surface during the deposition process as result of the oxidation of
the hypophosphite in the substrate surface [21]. Furthermore, NH4+ ions derived from the
NH4HF2 can combine with OH- ions [44] from the Mg(OH)2, according to the following
reactions:
Mg (OH )2(s )❑→ Mg (II)(ac)+2OH (ac )−¿ ¿ (1)
2 NH¿+¿+2OH (aq)
−¿ ❑→
2 NH 3(aq )+2 H 2 O( l)¿¿ (2)
___________________________________________
Mg (OH )2(s )+2 NH ¿+¿❑
→Mg ( II )(aq)+2 NH 3(aq)+2 H 2O(l)¿ (3)
Thus, Mg2+ ions provided by the Mg(OH)2 are available to react with fluoride ions from
NH4HF2 in the solution (33), forming MgF2 (34):
Mg (OH )2(s )+NH 4 HF2(ac)❑→ MgF2+NH 3(ac )+2 H 2O(l ) (4)
14
Figure 5. Scanning electron micrographs (secondary electrons) of the magnesium surface after (a) 0, (b) 15, (c)
30 and (d) 60 s of immersion in the alkaline electroless Ni-P plating bath
After 60 s of immersion, the transformation process of the Mg(OH)2 had progressed and
lamellar Mg(OH)2 was no longer observed (Figure 5 (d) and Figure 6). The backscattered
electron image of Figure 6 (b) reveals particles of light appearance, which correspond to the
Ni-P coating. The pseudocubic crystals that were present after 30 s have been transformed
into well-defined cubic crystals, with smooth facets with sizes typically in the range from
about 0.5 to 1 μm. The crystals are later identified as NaMgF3. Similar morphological changes
of MgF2 to NaMgF3 were observed by Sevonkaev et al. from mixing of a solution of MgCl2
and NaF at 80 °C [36]. They observed the formation of spherical particles of MgF2 that were
produced by aggregation of nanosize precursors. The particles were subsequently transformed
to cubic NaMgF3, with the rate of formation of the latter depending on the concentration of
NaF. Our findings of cubic crystals of NaMgF3 are consistent with the morphological
observations of these authors [36].
Figure 6. Scanning electron micrographs ((a) secondary electrons and (b) backscattered electrons) of the
magnesium surface after 60 s of immersion in the alkaline electroless Ni-P plating bath.
15
Figure 7 presents scanning electron micrographs that show the details of the transformation
during immersion of the magnesium in the electroless Ni-P plating solution for times from 15
to 60 s. The micrograph of Figure 7 (a) shows a spherical particle typical of those present on
the surface after immersion in the plating bath for 15 s. Figure 7 (b) reveals an intermediate
stage of the transition following immersion in the plating bath for 30 s; the particles display
the development of a cubic appearance. Figure 7 (c) shows that after immersion for 60 s
smooth-sided cubic crystals were fully developed. Figure 7 (d) shows the results of EDX
analysis of a region on the magnesium surface remote from the pseudocubic crystals formed
following immersion for 30 s in the alkaline electroless Ni-P plating bath. Figure 7 (e)
presents the analysis of a cubic crystal formed after a longer period of immersion of 60 s. The
analyses at both locations revealed the presence of oxygen, fluorine, magnesium and sodium.
The high concentration of magnesium that was detected at both locations (see Table 3)
resulted from detection of X-rays generated from the magnesium substrate in addition to those
generated in the reaction products. The presence of sodium and fluorine with an atomic ratio
close to 1:3 at the site of the cubic crystal (Figure 7 (e)) is consistent with the formation of
NaMgF3. The oxygen that was also detected possibly originates from Mg(OH)2, which may be
present along with MgF2 beneath the crystal. The significantly lower Na:F ratio of about 1:6
for the surface layer analysed in Figure 7 (d) suggests that both MgF2 and NaMgF3 are
present, in addition to Mg(OH)2. The localized formation of the MgF2 and NaMgF3 particles
is possibly due to the availability of a sufficient concentration Mg2+ ions to nucleate precursor
MgF2 particles; this may be preferentially achieved at defect sites in the passive film where
the film is less protective.
16
Figure 7. Scanning electron micrographs (secondary electrons) of the transformation process of MgF2 into
NaMgF3 after (a) 15 s, (b) 30 s and (c) 60 s of immersion in the alkaline electroless Ni-P plating bath. (d,e) EDX
spectra of the magnesium surface after 30 s of immersion at locations indicated in (b) and (c), respectively.
Previous studies [45,46] have shown that the Mg(OH)2/MgF2 film formed on magnesium
substrates in solutions containing fluorides is porous. In addition, the high reactivity of the
magnesium that is accessible to the electroless plating solution favours the reduction of nickel
on the Mg(OH)2/MgF2 layer, creating nucleation points for the growth of the Ni-P coating.
Hence, two morphologies are evident after 60 s, corresponding to the nickel and NaMgF3.
Table 3. Compositions (at.%) of the regions shown in Figure 7 after 30 s and 60 s of immersion in the alkaline
electroless Ni-P plating bath, determined by EDX analysis.
O F Na Mgfilm region (30 s) 3.5 7.3 1.2 88.0cubic crystal (60 s) 6.8 33.8 9.0 50.4
17
Figure 8 (a) shows that after 120 s of immersion, more Ni-P nodules had formed around the
pre-existing nodules. The Ni-P deposition then continued in an autocatalytic manner (Figure 8
(b)). After 600 s, much of the magnesium surface was covered by Ni-P nodules and NaMgF3
crystals were embedded in the coating (Figure 8 (c)). After 1800 s of immersion, the surface
was fully covered by the coating (Figure 8 (d)).
Figure 8. Scanning electron micrographs (secondary electrons) of the magnesium surface after (a)
120, (b) 300, (c) 600 and (d) 1800 s of immersion in the alkaline electroless Ni-P plating bath
Figure 9 shows the morphological evolution of the AZ31B alloy surface after (a) 0, (b) 15, (c)
60, (d) 120, (e) 300, (f) 600, (g) 1200 and (h) 1800 s of electroless Ni–P treatment. After 15 s
of immersion, a change of the surface morphology and the presence of some nickel nodules
were evident. The morphological change is similar to that observed on magnesium, indicating
the transformation of Mg(OH)2/MgF2. After 60 s of immersion, the hydroxide/oxide layer
appeared to have been dissolved or transformed, with NaMgF3 particles (see arrows in Figure)
being present on the surface. After 120 s of immersion the number of nickel nodules was
18
increased. By 1200 s of immersion, the nodules had increased in size, coalesced and covered
completely the surface. The coverage of the surface occurred at a faster rate than on pure
magnesium.
The coating development on the magnesium and AZ31B alloy was also investigated by XRD;
the results are presented in Figure 10. In the XRD pattern for magnesium (Figure 10 (a)),
peaks of Mg, Mg(OH)2, Al2O3 are present. The presence of Mg(OH)2 is due to the alkaline
cleaning process, as mentioned above. Since the surface was pre-treated using alumina
blasting, alumina particles were embedded in the soft magnesium alloy, which explains the
presence of characteristic peaks of Al2O3 in the XRD patterns. Additional peaks of NaMgF3
are observed at 60, 120 and 300 s of immersion in the electroless Ni-P plating bath, which
corresponds to the cubic species present in the SEM micrographs at the same times. The
presence of a peak centered at 2Ɵ = 45° for Ni (111) is observed after 300 s of immersion,
Finally, after 1800 s immersion, in addition to the substrate peaks, three broad peaks at 2θ =
44.48, 77.02 and 93.24 are evident, attributed to Ni (111) or (200), Ni (220) and Ni (311),
which correspond to the cubic phase of nickel and indicate the crystalline nature of the
coating due to the low concentration of phosphorus in the coating [47]. The peak broadening
at 1800 s is related to a slight distortion of the crystal structure of nickel caused by
phosphorus atoms in the coating [48].
19
Figure 9. Scanning electron micrographs (secondary electrons) of the surface of the grit-blasted AZ31B alloy
after (a) 0, (b) 15 (c) 60 (d) 120, (e) 300 (f) 600, (g) 1200 and (h) 1800 s of immersion in the alkaline electroless
Ni-P plating bath.
20
The results of the XRD characterization of the coating development on AZ31B substrate are
similar to that observed for magnesium (Figure 10 (b)). The main difference, additional to the
presence of Mg17Al12 phase due the β-phase of the substrate, lies in the rate of formation of
coating, which was higher for the initial deposition times on the AZ31B substrate. The
increased rate of deposition is indicated by broad peaks around 2Ɵ = 45° in the XRD patterns
from 60 s (Figure 10 (b)) due to the presence of nickel in the coating, compared with after 300
s for the magnesium substrate. This can be explained by taking into account that, as for the
magnesium, the α phase (Mg) of AZ31B alloy tends to form MgF2 on its surface, while the β
phase (Mg17Al12) tends to form soluble compounds, such as (AlF6)3− [49]. The electroless bath
provides a high pH environment which solubilizes (AlF6)3−. Such a dissolution generates
anodic areas on the alloy surface that generate electrons that catalyze the reduction of nickel
ions and increase the disposition rate [49,50]. The increased initial deposition rate on the alloy
compared with magnesium is evident in the weight gain measurements shown in Figure 12.
Figure 10. XRD patterns of (a) magnesium and (b) AZ31B after different times of immersion in the alkaline
electroless Ni-P plating bath.
21
However, for immersion times greater than about 1000 s, faster growth occurred on the
magnesium than on the alloy. It is proposed that this may be due to the presence of a zinc-
enriched layer in the alloy (confirmed later by the results of RBS). The zinc-enriched layer
may promote the formation of a coating with reduced porosity [51–53] and hence limit the
access of the plating solution to the substrate. Accordingly, less magnesium is released to the
plating bath by corrosion of the substrate. This minimizes the reduction of Ni2+ ions within the
Ni-P plating solution by released magnesium, which can cause a reduced deposition rate of
nickel on the substrate.
Figure 11 presents the results of RBS analyses of the grit-blasted magnesium and AZ31B
alloy after the cleaning pre-treatment that involved immersion in an alkaline solution of 37
g/L NaOH and 10 g/L Na3PO4 for 600 s at 60 oC. Both substrates revealed yields from oxygen
and magnesium. The yields are consistent with a observations of Mg(OH)2 lamellae on the
surface by SEM. In addition to Mg(OH)2, the film may also contain hydrated MgO. The layer
on the alloy probably also contains aluminium oxide/hydroxide. However, the yields from
aluminium in the spectra are similar for both substrates, which indicates that they originate
mainly from particles of alumina that were embedded in the substrates during grit-blasting.
The presence of embedded alumina was also identified in the XRD results of Figure 10. The
edge due to scattering from magnesium beneath the oxide/hydroxide layer was not sharp for
the magnesium substrate compared with that for the alloy, which may be due to a greater
roughness of the substrate and less uniform thickness of the oxide/hydroxide layer at the
location of the analysis on the magnesium compared with the alloy. The fitting of the data for
the AZ31B alloy indicated that ~ 5 ± 1 x 1017 oxygen atoms cm−2 were associated with the
film. From the atomic densities of oxygen in MgO and Mg(OH)2 (5.32 x 1022 and 5.12 x 1022
atoms cm-3), a film of about 100 nm thickness can be estimated. The roughness of the
substrate precluded estimating the film thickness. Between channels 300 and 400 the
spectrum for the AZ31B alloy shows a yield due to the presence of zinc, with a peak near 22
channel 390. The peak is due to enrichment of zinc at the in the alloy at the interface between
the alloy and the MgO/Mg(OH)2 layer. The enrichment corresponds to ~ 1.6 x 1015 zinc atoms
cm−2. Enrichments of alloying elements that are more noble than magnesium have been
reported previously to form beneath both oxide- and fluoride-containing films on magnesium
alloys [54]. Usually, these enriched alloy layers are only a few nanometers in thick [9]. In the
case of an anodized AZ31 alloy, an enrichment of 6.2 x 1015 zinc atoms cm-2 was measured,
which was estimated to be equivalent to a concentration of 29 at.% zinc in an enriched alloy
layer of 5 nm thickness [55]. Therefore, the present enrichment suggests that a relatively high
average concentration of zinc has been developed by the alkaline cleaning process. The
spectrum for the magnesium also shows the presence of relatively heavy elements in the range
of channel numbers from 300 to 400; the yield in the range is probably due mainly iron,
nickel and copper impurities in the magnesium.
Figure 11. RBS spectra for the magnesium and AZ31B alloy after the cleaning process in an alkaline solution of
37 g/L NaOH and 10 g/L Na3PO4 for 600 s at 60 oC.
23
The above findings with regard to the development of the coating, as well as earlier
observations by SEM, are supported by the measurements of the OCP during the deposition
over a period of 1800 s, which are shown in Figure 12. For both substrates, three stages are
distinguished: (i) an initial drop in potential to a minimum value, which is associated with the
predominance of oxidation of the substrate and formation of Mg(OH)2, MgF2 and NaMgF3
(Figures 5 and 9 (b,c)) (ii) a rise in potential as nucleation of the Ni-P coating becomes
increasingly significant and reduction of both nickel and hydrogen ions occurs [21]. (Figures
8 (a) and 9 (d)), and (iii) a slowly rising potential that occurs when the coating has covered the
substrate and increases in thickness (Figure 8 (c) and 9 (f)). The first period is more prolonged
for magnesium (180 s) than for AZ31B alloy (100 s).
Figure 12. Plots of (a) weight gain as a function of time following immersion and (b) variation of the OCP with
time during the immersion, of both pure magnesium and AZ31B alloy in an alkaline electroless Ni-P plating
bath.
24
A rough surface is created by alumina grit blasting. During alkaline cleaning, a layer
Mg(OH)2 is formed, which is subsequently transformed on immersion in the electroless Ni-P
plating bath into MgF2 that passivates the surface. Localized reaction between the MgF2 and
sodium and fluoride ions in the bath results in formation of cubic NaMgF3 crystals above the
passive layer. Figure 13 shows cross-sections of the coatings formed on the magnesium the
AZ31B alloy after immersion for 1800 s in the electroless Ni-P plating bath. The cross-
sections reveal coatings of total thickness 6.5 and 6.0 μm on the respective substrates. Cubic
NaMgF3 crystals are located in a layer of thickness up to ~ 2.5 μm at the base of each coating.
The crystals are partially embedded in the electroless nickel deposit. In a previous study [8], it
was shown that the coatings on magnesium adhered well to the substrate, with a bond strength
of ˃ 9.3 MPa. However, further investigations are necessary to determine the role of the
cubic NaMgF3 crystals on the mechanism of bonding, and whether they can reduce the bond
strength or enhance it, for instance by mechanical keying of the coating to the substrate.
According to the previous discussion of the mechanism of growth of the coatings, a schematic
overview of the Ni-P formation process on the magnesium and the AZ31B alloy is presented
in Figure 14.
Figure 13. Cross-sections of (a) magnesium and (b) AZ31B alloy following immersion for 1800 s in an alkaline
electroless Ni-P plating bath.
25
Figure 14. Schematic overview of the process of formation of Ni-P coating on magnesium and AZ31B alloy.
Corrosion and wear tests that were carried out in previous work [8,10] indicated that the
presence of NaMgF3 particles within coatings of much greater thickness (about 6.0 to 6.5 μm) 26
than the size of the NaMgF3 particles (about 1-2 μm) have no major impact on the corrosion
protection of the magnesium substrate by the coatings. Whether there is an influence of the
particles on coatings of a few microns thickness, where particles are either located close to the
coating surface or exposed at the surface, remains to be investigated.
4. Conclusions
1. The dependence of the surface roughness produced by either grinding or grit-blasting on
the rate of formation of an alkaline Ni-P electroless coating on magnesium has been
determined. Alumina grit blasting produced the roughest surface and the highest rate of
coating formation. In contrast, grinding with SiC papers resulted in progressively reducing
rates of coating growth as the grit size was reduced. The results are explained by effect of the
mechanical treatments on topography of the magnesium surface and the amount of plastic
deformation of the substrate, with the rougher surface increasing the number of favorable sites
for nucleation of the Ni-P coating.
2. The study shows in greater detail than previously available the development of the Ni-P
coating from early times of immersion in the electroless Ni-P plating bath. The presence of
fluoride ions from NH4HF2 reagent and sodium ions from NaH2PO2.H2O reagent in the
electroless solution promotes the formation of fluorinated species, including MgF2 and
NaMgF3, on the magnesium and AZ31 alloy surfaces. MgF2 is formed after a few seconds of
immersion in the electroless solution and passivates the surface. At local sites, a relatively low
population density of cubic NaMgF3 particles, with a size of about 1 μm, are developed from
spherical MgF2 particles. Such a morphological transformation has only been reported
previously from studies of mixed solutions of MgCl2 and NaF, in contrast to the present
observations of the transformation on magnesium surfaces during electroless plating.
27
3. At about the same time as particles of MgF2 and NaMgF3 are forming, spherical particles of
Ni-P are deposited; these particles subsequently increase in number and size and spread across
the substrate surface to eventually envelop the NaMgF3 crystals. The crystals then become
covered by further growth of the Ni-P coating and remain at the coating base. The presence of
the fluoride species in the electroless Ni-P plating bath allows the Ni-P coating to form
without significant corrosion of the magnesium substrate and avoids the decomposition of the
electroless solution due to the presence of Mg2+ ions released by corrosion of the substrate.
4. Finally, according to gravimetric measurements, SEM and XRD results, the plating process
is initially faster on the surface of the AZ31 alloy than on the pure magnesium, which is
suggested to be related to an enrichment of zinc in the alloy substrate.
Acknowledgements
The authors are grateful to “Departamento Administrativo de Ciencia, Tecnología e
Innovación–COLCIENCIAS (project 111545221131)”, Universidad Pontificia Bolivariana,
University of Antioquia and University of Manchester. The authors also thank the
Engineering and Physical Sciences Research Council (U.K.) for financial support
(Programme Grant: LATEST2) and Professor Jun Yen Uan, Department of Materials Science
and Engineering, National Chung Hsing University (Taiwan) for supply of the AZ31B
magnesium alloy. They also thank the European Community for financial assistance within
the Integrating Activity “Support of Public and Industrial Research Using Ion Beam
Technology (SPIRIT)“, under EC contract no. 227012.
28
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34