Effects of surface morphology on erosion–corrosion and corrosion resistance of highly hydrophobic nickel-tungsten electrodeposited film

Hard nanocrystalline Ni-Co or Ni-W coatings are receiving a growing interest owing to their premium hardness, wear, and corrosion properties for several industrial applications. Furthermore, surface hydrophobicity greatly improves surface corrosion resistance. In this research, the durability of hydrophobic hierarchical NiW electrodeposited film has been evaluated in a high-speed slurry erosion–corrosion (EC) test rig. Two different coatings have been tested: a rough coating obtained in a chloride-based bath (NiWchloride) and a smooth coating obtained in a sulfate-based bath (NiWsulfate). Corrosion behavior over time was evaluated by electrochemical impedance spectroscopy (EIS), while surface hydrophobic performance was determined by the sessile drop method. The morphological features of the coatings were assessed by scanning electron microscopy while roughness modification during the EC tests were identified by means of an atomic force microscopy. During static immersion in the aggressive solution, the impedance modulus of the coatings continuously increased due to an increase in the thickness of corrosion products. During the EC test, the impedance modulus of the smooth NiW coating decreased, losing its barrier property. It was observed that the increase in impedance modulus of the hierarchical structure of the rough NiW coating during EC was far greater than that during static immersion. After 64 min of EC, the NiWchloride was able to resume its hydrophobicity property by storing in air; nevertheless, the NiWsulfate, with a loss of approximately 72% in its initial contact angle, was no longer hydrophobic. The results showed improvements in the lifetime of hydrophobic NiW coatings in erosion–corrosion conditions of the hierarchical nanostructure obtained in a chloride-based electroplating bath.