Structure, Microhardness and Corrosion Properties of the Electrodeposited Ni-BN Nanocomposites

Structure, Microhardness and Corrosion Properties of the Electrodeposited Ni-BN Nanocomposites | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Structure, Microhardness and Corrosion Properties of the Electrodeposited Ni-BN Nanocomposites Ranjeet Singh, Aniket Singh, Alok Kumar Chaudhari, Randhir Kumar, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7241823/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study investigates the co-deposition, characterization and applications of nickel/boron nitride (Ni/BN) nanocomposites prepared by electrodeposition on copper plate from an ethylene glycol-based electrolyte. The main objective was to evaluate the impact of boron nitride (h-BN) incorporation on the corrosion resistance, surface morphology, microstructure and microhardness of the nickel matrix. Powder X-ray diffraction (p-XRD) analysis shows the layout of nanocrystalline coatings with grain refinement observed upon BN incorporation. A shift in preferred orientation and lattice strain indicated successful particle incorporation without phase transformation. Scanning electron microscopy (SEM) shows that Ni/BN coatings manifest finer, smoother, and more compact surface morphologies than pure Ni coatings. Vickers microhardness testing showed a significant increase in hardness with BN addition, reaching maxima of 415 HV at 1.0 A/dm² because of dispersion strengthening and grain boundary pinning effects. Potentiodynamic polarization analysis in 3.5 wt% solution of NaCl demonstrated enhanced corrosion resistance of the Ni/BN nanocomposite coatings compared to Ni, attributed to the barrier effect of uniformly distributed BN nanosheets and enhanced passive film stability. The results suggest that electrodeposited Ni/BN nanocomposites are better materials for applications requiring improved mechanical strength and corrosion resistance. Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 INTRODUCTION Over the last few decades, many researchers concentrated on the field of material and metallurgy to develop new materials with enhanced properties having low cost and better ecological impacts, one of them is metal matrix nanocomposites (MMNC’s) [ 1 , 2 ]. In recent times MMNC’s increased their industrial applications in different areas such as aerospace, automobile, electronic packaging, structural engineering etc. due to their magnificent properties [ 3 – 5 ]. Ni is one of the most widely used alloying metals all over the world due to its better wear and corrosion resistance. Ni and its compounds can be used in a vast amount of coating, which have good thermal and electrical conductance, high strength, corrosion resistance, good reflection of light. Ni based composite materials are commonly used in aerospace, military, health care, construction, instrumentation, marine, petroleum and biochemical industries [ 6 , 7 ]. Ni matrix composite can be prepared by different types of methods with low cost, good reproducibility and reduced energy consumption. Many researches shows that thin film of other element coated with Ni up to few nanometres have same hardness as bulk nickel. By this process great improvement in electro mechanical system devices can be achieved by Ni coating. Electrodeposition, also called as electroplating, is defined as the electrochemical process where an electroplated coating is formed on the substrate surface by reducing metal ion from an electrolyte [ 8 , 9 ]. Among the other techniques for preparing MMNC’s, electrodeposition is found to be beneficial in improving several functional properties such as precised control over shape, structure and thickness of the electroplated deposits [ 10 ]. By conventional choice of operation conditions and bath composition, the properties of the deposits can be modified as per specific applications [ 11 – 13 ]. Composite electrodeposition is the method of incorporating the other element grains into the metal matrix during the electrodeposition process. Nitrides such as AlN, TiN, BN, carbides such as SiC, B 4 C, nanorods, nanotubes etc. are commonly used as reinforcement. Introduction of nano reinforced particle in to metallic matrix was found beneficial in improving several functional properties like as surface hardness, surface morphology, corrosion resistance, wear resistance, electrical and magnetic properties [ 14 ]. Several times, it also alters the structural parameters of the metallic matrix because of incorporation of impurities and additives for example lattice parameter, grains size and strain, internal stresses (residual stresses), deposition rate, electrolyte composition and pH, crystal orientation (texture), phase formation and solid solution effects [ 15 ]. Hardness of nanocomposites was found to be increased by a significant amount than that of the pure metal. BN is a white, soft, lubricious powder and exists in various form including hexagonal, cubic, and wurtzite phases, each form have their distinct properties. Boron nitride, a 2D material, shares a similar structure and lattice constants with graphene. The layer consists of sp 2 covalent bonds between boron and nitrogen atoms, while between the layers weak Van der Waals interactions exist. Its use in catalysis is primarily attributed to its chemical and thermal stability, as well as its excellent thermal conductivity [ 16 – 18 ]. Recently, h-BN has been identified as a catalyst or co-catalyst, capable of forming heterogeneous structures with other substances, facilitating cooperative catalysis and enhancing the catalytic performance of the system. BN possesses electrical insulating properties, high dielectric breakdown strength, exceptional thermal conductivity, high volume resistivity (10 8 − 10 13 ohm cm), and maintains excellent chemical stability at high temperature [ 19 , 20 ]. There are many researches where incorporation of BN into nickel matrix has been performed and results of polarization studies shown that corrosion resistance of the coatings has been enhanced because of barrier effect of incorporated BN particles, in contrast with pure Ni. Gyawal et. al. have described that the corrosion resistance of BN incorporated Ni composite is increased about 12 times than Ni coating. Enhanced incorporation of boron nitride in the nickel matrix was found to improve hardness and wear resistance, regardless of boron nitride is soft [ 21 ]. However, co-deposition of different ceramic particles has been studied by several researchers but co-deposition of boron nitride in nickel matrix and its effects on the structural features and functional properties like microhardness and corrosion resistance have not been well studied yet. Ni/BN could be a good candidate for an improved corrosion resistance and hardness. The aim of the present study was to synthesize BN incorporated nickel matrix nanocomposite coatings by electrodeposition method and to examine its effect on the microstructure, microhardness, surface morphology and electrochemical corrosion properties of the coatings. In addition, attempts will be made to explain composition property relationship for precise tailoring of the properties having smooth, compact, pore, gap and crack free surface. EXPERIMENTAL Ni-BN nanocomposites were deposited on commercial grade copper cathode (substrate) from an additive free bath using 100 g/L nickel sulphate and boron nitrite (Sigma Aldrich) and 30gm/L boric acid in ethylene glycol. Chemicals were analytically grade and used as received. Commercial grade copper plates were used as cathode having dimension of 2.0 cm x 1.0 cm x 0.1 cm. Initially, the cathode was mechanically polished using different grades (1/0, 2/0, 3/0 and 4/0) of emery paper for obtaining scratch free and smooth surface. Finally, disc polishing on the fine quality sylbeth cloth with few drops of Grade II Alumina Polishing solution (Geologists Syndicate Pvt. Ltd., India) was used to obtain stain free, reflective and smooth surface. For degreasing of the Cu strips they were immersed in acetone for five minutes and then gently washed with distilled water. After polishing, copper cathode was positioned between the two parallel rectangular anodes of pure nickel. 100 mL of plating solution in a glass cell (450 mL capacity) was utilized as the electrolysis cell. Homogeneous suspension of boron nitride nano-particles in the plating bath was maintained by making a slurry of particles in small amount of solvent and transferring it to appropriate amount of solvent and then by magnetic stirring for 8 hours. The stability of suspension in the bath during electroplating was maintained by continuous magnetic stirring. To get coatings with constant thickness, electro-co-deposition was performed at varying current densities and plating time at 35̊C. Optimum electroplating condition was accomplished by changing one plating parameter once and keeping all the others to a fixed value. After electrodeposition, the surface of cathode was cleaned ultrasonically for 05 minutes. The crystal structure of the Ni/BN composite coatings was analyzed using powder X-ray diffraction (p-XRD) with a Bruker D2-PHASER, benchtop X-ray diffractometer, employing CuKα radiation (λ = 1.541836 Å) over a 2θ range of 10°–90°. Lattice strain and crystallite size were determined from the most intense diffraction peak. Crystallite size (D) of the coatings was calculated using the formula D = λ/βcosθ, and the strain (η) using η = β/4tanθ, where θ is the corresponding Bragg angle and β is the integral breadth. Surface morphological features and chemical constituents of the deposits were examined via scanning electron microscopy (W-SEM, JEOL, JSM6010LA) equipped with an energy-dispersive X-ray analyzer (EDAX). Elemental composition results, reported in the weight percent (wt%), represent the average of four to six measurements. Corrosion studies were performed with the help of potentiostat coupled with impedance unit (PalmSens, EmStat4s) in a solution of neutral 3.5% NaCl. The Tafel curves for corrosion characterization were recorded at the potential range from − 0.5 to + 1.0 V vs SCE. Microhardness (Hv in Kgf mm − 2 ) measurement of the deposits was performed using digital Vickers microhardness tester (Fine Testing Instruments, India, Model: HVD-100 MT) at 10 gram applied load for 10 seconds. To avoid any substrate effect, average of 10 measurements were taken to get final values. RESULTS AND DISCUSSION X – ray diffraction Studies: Powder XRD technique was used to determine the phase and crystalline size of the Ni and Ni/BN nanocomposite coating at various current densities. The characteristics XRD peak of nickel deposited at 0.5 A/dm 2 and 1.5 A/dm 2 and Ni-BN deposited at 0.5 A/dm 2 and 1.5 A/dm 2 are presented in the Fig. 1 . A gradual change in the intensities of peak with current density clearly indicates that the deposition current density plays a very significant role in structural properties and composition of the coating. Relative texture coefficient (RTC) was calculated to analyse the orientation of crystallites. XRD patterns of the Ni particles exhibit typical intense lines appearing at 2θ = 44.17(111), 51.67(200) at current density 0.5 A/dm 2 and 2θ = 44.12(111), 51.57(200), 76.28(220) at current density 1.5 A/dm 2 . Ni-BN composite shows intense line at 2θ = 44.51(111), 51.76(200), 76.18(220) at current density 0.5 A/dm 2 and 2θ = 44.46(111), 51.81(200), 76.57(220) at current density 1.5 Adm − 2 . Texture coefficient calculation of nickel deposit at 0.5 A/dm 2 indicated (200) plane as the predominant orientations and changed to (220) plane as the current density increases to 1.5 A/dm 2 (Table 1 ). Preferred orientation of Ni-BN composites was (220) plane for current densities 0.5 A/dm 2 and as the current density increases preferred orientation shifted to (200) planes at 1.5 A/dm 2 (Table 1 ). From the presented curves of XRD it was analysed that at current density 0.5 A/dm 2 , the preferred orientation of composite after reinforcement of BN in Ni composite shift from (200) to (220). Grain size of nickel was 27.6 nm at current density of 0.5 A/dm 2 whereas it was found to be 16.2 nm for 1.5 A/dm 2 . The result confirmed the formation of fine-grained deposits when the current density enhances. After the reinforcement of BN in Ni composite there is significant change in crystallite size was observed and it was observed to be 22.5 nm and 16.77 for current density 0.5 and 1.5 A/dm 2 respectively. A decrease in grain size indicates the grain refinement as well as fine reinforcement of BN particles in Ni matrix. A raise in current density leads to a higher over potential, which boosts the rate of nucleation and consequently promotes refinement of grains. The co-deposition of BN ceramic particles with the Ni matrix explains the certain peaks disappearance in the XRD data, while the size of grain of the nickel matrix remains unaffected by the presence of BN particles at higher current density. In all XRD analysis of Ni-BN coatings, the co-deposition of BN ceramic particles creates additionally nucleation centre, thereby inhibiting crystal growth. Pompei et. al. reported that incorporation of BN particles in the nickel matrix favours the loss of orientation of pure Ni deposits [ 22 ]. Also, BN particle incorporation does not affect the grain size of metal matrix. It has been also reported that co-deposition of fine ceramic particles with metals leads to reduction in grain size. This is because of the inhibition of normal growth of grain and the promotion of new nucleation sites induced by the particles of second-phase as seen at lower current density in present study. The Ni-BN phase provides lattice parameter between 3.525Å to 3.534 Å which is slightly higher compared to the pure nickel standard value (3.517Å). Lattice strain of all the coatings was observed very small (0.00248 to 0.005456). The calculated strain of the nanocomposite coatings are low, which can be ascribed to the reduced deformation caused by ceramic particles, as they are in a closely strain-relaxed state. Other than Ni and Ni-BN matrix no peak was found there in the XRD patterns which indicate that the composites have not gone through any phase transition within the given temperature range. Table 1 Crystallite size, strain and relative texture coefficients of nickel and Ni-BN coatings at different current densities. Composite Current density A/dm 2 Crystallite size (nm) Strain Relative texture coefficient (111) (200) (220) Ni Ni Ni-BN Ni-BN 0.5 1.5 0.5 1.5 27.6 16.2 22.5 16.8 0.003239 0.004893 0.003534 0.004733 0.06 0.94 --- 0.07 0.20 0.72 0.31 0.49 0.19 0.06 0.09 0.98 Effect of current density on wt% incorporation of BN in nickel matrix: Current density is extremely widely considered parameter in the electrodeposition process. Changes in current density range of 0.5 to 2.5 A/dm 2 influenced the quality of the deposits, with the best quality achieved at current densities between 0.5 to and 1.0 A/dm 2 . For enhanced current densities, deposit quality declined, leading to blunt deposits and effects of burning at the edges of the deposited plates. Figure illustrates the correlation of current density and the BN content in the Ni-BN deposits. As current density increased from 0.5 A/dm 2 to 2.5 A/dm 2 , the content of BN in the deposits at first increased to 5.1% on current density 1.0 A/dm 2 and after that gradually decrease to 3.6% as current density increased to 2.5 A/dm 2 . The variation in BN particle with respect to current density in the alloy composite is believed to be influenced by the availability of BN particles at the cathode surface, the discharge of ions through current density and the enmeshment of particles in the producing alloy. Tripathi et. al. reported that BN content incorporation in coating firstly increased with enhancement in current density, then reached up to maximum, thereafter followed a sharp decrease as current density increases [ 23 ]. It is assumed that Metal ions adsorb onto the surface of particle, so the rate of particle incorporation is directly related to the rate of metal deposition. However, metal deposition rate, which remains kinetically controlled, continued to increase with current density, causing a tremendous decline in content of BN particles. The phased decrease in content of particles beyond one can be attributed to diffusion control with metal and discharge occurring under a mixed kinetic and diffusion control regime. The decrease in boron nitride particle content beyond a specific current density may be attributed to transition from kinetic control to diffusion controlled. As the particle reinforcement process become diffusion controlled, its rate stayed constant despise of increase in current density. Microhardness Studies: Microhardness of Nickel and Ni-BN nanocomposite coatings were calculated by Vicker’s microhardness test. The pure Nickel coating without any reinforcement deposited at current density 0.5A/dm 2 has hardness of 273 HV. Further it increased to 334HV when current density enhances to 1.5 A/dm 2 and after that as the current density enhances the microhardness of the deposits decreases gradually up to 267HV at current density 3.0 A/dm 2 .The Addition of BN to the nickel matrix raises the microhardness to about 332 HV at current density 0.5 A/dm 2 which further increased to 415HV at current density 1.0 A/dm 2 and then gradually decreases as the current density increases. At current density 1.0A/dm 2 , the Ni-BN composite has significantly higher hardness than the pure nickel coating. This could be because of dispersion strengthening from the integrated BN particle into the matrix metal. Li et. al. reported that the incorporation of BN in Ni-W alloy clearly shows that the cross-section microhardness of coating increases towards the surface[ 16 ]. Paydar et. al. reported that incorporation of Boron nitride and Boron carbide into Ni matrix show the increment in microhardness as there is increase in current density[ 24 ]. The reduction in hardness after reaching the maximum value follows a pattern similar to that of the particle content of the composites. The trend of hardness with change in current density indicates that hardness is dependent on size of crystallite. The improvement in micro hardness of the Ni/BN coating can be ascribed to (a) the dispersive strengthening effect of BN, (b) the restriction of crystalline bulk growth by BN nanosheets during electrodeposition, which refines the nickel crystallites,(c) the packing of grain boundary and dislocation motion in the Nickel matrix by the BN nanosheets. A lesser crystallite size means a higher grain boundaries number, which hinder motion of dislocation, resulting in harder materials. The uniform distribution of boron nitride particles in the coatings likely results in a high number of particles located at the grain boundaries, which obstruct dislocation movement and prevent dislocation slip, thereby increasing the hardness of the deposits. Surface Morphology: The surface morphology of incorporated boron nitride in nickel composite coating was analysed by scanning electron microscope (SEM) at various magnification. Figures 4 and 5 displays surface morphologies of Ni and the Ni/BN nanocomposite coatings, respectively. The electrodeposited composite coating clearly exhibits a surface which is smooth and have finer grains compared to the Ni coating. Previous studies have reported that codeposition of fine ceramic particles within a Ni metal matrix leads to grain size reduction, primarily due to the repression of normal growth of grain and the promotion of nucleation facilitated by the presence of second-phase particles. As shown in Fig. 5 , BN particles were successfully co-deposited into the Ni matrix, as indicated by the dark voids observed in the image. The incorporation of BN ceramic particles significantly influences the structural and morphological characteristics of the Ni matrix. The SEM image exhibits that the entire electrodeposited metal matrix has fine granular structure with uniform grain distribution. The interface between boron particle and matrix phase is very small and thus cannot be clearly distinguished. However, it is evident from the SEM images that the crystal grains on the surface of the composite layer are smooth and evenly distributed. Li et.al. reported that incorporation of Boron Nitride in Ni-Co alloy shows that there is no obvious gap and pores on the surface [ 25 ]. The Spherical Convex structures were smooth and compact and as the current density varied, the gaps between the large convex structures gradually disappeared, leading to improved compactness in the micro-nanostructure of the coating. However, EDAX analysis shows uniform distribution of the BN particle into metallic matrix. All the nanocomposite coatings were observed to be free of cracks and pores having closely smooth surface. Corrosion Studies: The corrosion behaviour of Ni and Ni/h-BN composite coatings was studied by monitoring after immersion in a neutral 3.5 wt% solution of NaCl until it stabilized. The polarization curves for both nickel and Ni/BN nanocomposites at various current densities are presented in Fig. 6 . Pure nickel deposits exhibits a slight active-passive transition. In contrast, BN incorporated Ni/BN composite coatings display an extensive passive region as well as a significant positive shifting of corrosion potentials compared to Ni. These results clearly indicate that the reinforcement of BN into the metal matrix improves corrosion protection. Specifically, in the 3.5 wt% solution of NaCl, the corrosion potential of the Ni/BN nanocomposite increases with enhancement in current density from 1.0 to 2.0 A/dm 2 . The reduced corrosion rate of the Ni/BN composite coatings can be ascribed to both compact metallic matrix and the incorporated BN particles, which inherently provide improved corrosion resistance. Hsu et. al. found that for the Ni-P/BN composites the corrosion resistance improves significantly which is caused by barrier effect of boron nitride particles, compared to standard Ni-P coatings [ 26 ]. Similar analysis was also reported by Li et.al. for the incorporation of BN in Ni-Co alloy coating [ 25 ]. Furthermore, the structural modification of nickel crystallites, evidenced by changes in preferred orientation upon nanoparticle incorporation, contributes to improved corrosion resistance. Another possible explanation for the lower corrosion rate lies in the electrochemical mechanism [ 27 ]. Previous studies have shown that dispersing ceramic nanoparticles in nickel matrix, materials with positive standard potential more than nickel creates corrosion microcells, where the ceramic nanoparticles act as cathodes and nickel as anode. It promotes anode polarization, which may explain the enhanced corrosion resistance observed in Ni/BN composite coating. Conclusions In this study, Ni/BN nanocomposite coatings were successfully synthesized on copper plate by electrodeposition technique using an ethylene glycol-based electrolyte. The effects of BN incorporation and varying current densities on the mechanical, structural, and electrochemical properties of coatings were systematically examined. XRD analysis confirmed the formation of nanocrystalline structures with a change in preferred orientation and significant grain refinement due to the incorporation of BN particles. The crystallite size decreased with increasing current density, indicating enhanced nucleation and inhibited grain growth improved by the reinforcement of BN. The co-deposition of BN did not induce any new phase formation but changed the lattice parameters slightly, showing a strain-relaxed and stable composite structure. SEM imaging analysis observed that the Ni/BN coatings possessed smoother, denser, and more uniform surfaces equated to Ni coatings. The coatings were free from cracks and voids. Microhardness testing shows that the reinforcement of boron nitride significantly improved the microhardness of the Ni metal matrix, reaching a peak value of 415 HV at current density of 1.0 A/dm². This improvement is attributed to grain refinement, dispersion strengthening, and the inhibition or blocking of dislocation movement by the embedded ceramic particles. Electrochemical corrosion tests in 3.5 wt% solution of NaCl demonstrated enhanced corrosion resistance of the incorporated BN in Ni coatings compared to pure Ni, as evidenced by a positive shift in corrosion potential and lower corrosion current density. The improved corrosion behaviour is primarily due to the BN particles shows barrier effect and the formation of a sturdy passive layer on the coating surface. Overall, the results confirm that BN incorporation in nickel coatings via electrodeposition leads to significant improvements in both mechanical and corrosion-resistant properties. This makes Ni/BN nanocomposite coatings highly suitable for demanding applications in aerospace, marine, and industrial environments where durability and corrosion protection are critical. Declarations Competing interests The authors declare no competing interests. Ethical approval and consent to participate Not applicable. Consent to publish Not applicable. Funding Statement The authors acknowledge the funding from the Science and Engineering Research Board (File No. EEQ/2022/000530), New Delhi, India and University Grant Commission (F.30–505/2020-BSR), New Delhi, India. Author Contribution RS: conducted the research and characterization, AS: original draft righting, mechanical property study, AKC: conceptualization, methodology, data curation, review and editing, RK: analysis and contributed in preparing tables and figures, ES: corrosion study, PKR: optimization of plating bath, review and editing. Data Availability The datasets generated and analysed during the current study are available from the corresponding author on reasonable request. References -Malaki M, Tehrani AF, Niroumand B. Fatgiuebehavior of metal matrix nanocomposites. Ceram Int. 2020;46(15):23326–36. https://doi.org/10.1016/j.ceramint.2020.06.246 . -Chen W, Yang T, Dong L, Elmasry A, Song J, Deng N, Fu YQ. 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Gorakhpur University","correspondingAuthor":false,"prefix":"","firstName":"Aniket","middleName":"","lastName":"Singh","suffix":""},{"id":530644951,"identity":"37eeb95f-33fd-425c-a8c2-776ff9dcc245","order_by":2,"name":"Alok Kumar Chaudhari","email":"data:image/png;base64,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","orcid":"","institution":"D.D.U. Gorakhpur University","correspondingAuthor":true,"prefix":"","firstName":"Alok","middleName":"Kumar","lastName":"Chaudhari","suffix":""},{"id":530644953,"identity":"622cee8d-327a-4fab-b73f-0375a3fe3ba4","order_by":3,"name":"Randhir Kumar","email":"","orcid":"","institution":"D.D.U. Gorakhpur University","correspondingAuthor":false,"prefix":"","firstName":"Randhir","middleName":"","lastName":"Kumar","suffix":""},{"id":530644956,"identity":"a2d894ec-52bb-4802-a899-dc8be2f1c8e8","order_by":4,"name":"Ekta Sonker","email":"","orcid":"","institution":"D.D.U. Gorakhpur University","correspondingAuthor":false,"prefix":"","firstName":"Ekta","middleName":"","lastName":"Sonker","suffix":""},{"id":530644960,"identity":"c2d32554-a7c8-44e1-af0d-bd5ca5c18f0a","order_by":5,"name":"Pradeep Kumar Rao","email":"","orcid":"","institution":"D.D.U. Gorakhpur University","correspondingAuthor":false,"prefix":"","firstName":"Pradeep","middleName":"Kumar","lastName":"Rao","suffix":""}],"badges":[],"createdAt":"2025-07-29 09:53:31","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7241823/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7241823/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":93769509,"identity":"aaddf366-4114-41c4-9359-ee6ab00d635a","added_by":"auto","created_at":"2025-10-17 11:37:34","extension":"docx","order_by":0,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":3737784,"visible":true,"origin":"","legend":"","description":"","filename":"ElectrodepositionofNIBNSubmitted.docx","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/d5203c1773fab0d721f3552e.docx"},{"id":93769506,"identity":"9083c8d5-debe-4a11-95fc-302fb44c1fab","added_by":"auto","created_at":"2025-10-17 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11:37:34","extension":"html","order_by":16,"title":"","display":"","copyAsset":false,"role":"acdc-reference","size":87133,"visible":true,"origin":"","legend":"","description":"","filename":"earlyproof.html","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/9a6ac4f2c048704d47bc8bef.html"},{"id":93769504,"identity":"3dcdfcb5-2547-4326-bf0b-de7107c07afc","added_by":"auto","created_at":"2025-10-17 11:37:34","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":26762,"visible":true,"origin":"","legend":"\u003cp\u003eXRD pattern of Ni and Ni-BN composite at current density 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e and 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e.\u003c/p\u003e","description":"","filename":"floatimage1.png","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/63e885c59e4ced9818732b30.png"},{"id":93769503,"identity":"c1c46798-6623-41ca-a7ed-41487a9ae2cf","added_by":"auto","created_at":"2025-10-17 11:37:34","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":9567,"visible":true,"origin":"","legend":"\u003cp\u003eVariation of BN content in the electrodeposited composite at different current densities.\u003c/p\u003e","description":"","filename":"floatimage2.png","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/08686d66bdfa6ff09e37a51c.png"},{"id":93769505,"identity":"6451268b-91d2-4b80-b1d5-af78b6f23c7b","added_by":"auto","created_at":"2025-10-17 11:37:34","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":28944,"visible":true,"origin":"","legend":"\u003cp\u003eVariation in microhardness of Ni and Ni-BN deposits at various current densities.\u003c/p\u003e","description":"","filename":"floatimage3.png","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/db98f5e3df4e0962c89434f0.png"},{"id":93770200,"identity":"0d367a43-017f-43cf-8100-f520803195b2","added_by":"auto","created_at":"2025-10-17 11:45:34","extension":"jpeg","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":810362,"visible":true,"origin":"","legend":"\u003cp\u003eSEM images of Nickel coatings produced at different current densities (a), (b) \u0026amp; (c) 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e, (d), (e) \u0026amp; (f) 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e respectively.\u003c/p\u003e","description":"","filename":"floatimage4.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/6ed67971f98260df576e8130.jpeg"},{"id":93769514,"identity":"0b9a43be-feb3-4e77-9601-6625dd3de45f","added_by":"auto","created_at":"2025-10-17 11:37:34","extension":"jpeg","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":795784,"visible":true,"origin":"","legend":"\u003cp\u003eSEM images of Ni/BN composite coatings prodeced at different current densties (a) (b) \u0026amp; (c) 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e, (d), (e) \u0026amp; (f) 1.5 A/dm\u003csup\u003e2 \u003c/sup\u003erespectively.\u003c/p\u003e","description":"","filename":"floatimage5.jpeg","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/eb58ce6aaac3ea9705b95f27.jpeg"},{"id":93770199,"identity":"e7a614b5-2bbf-492a-a174-9d09eee5f445","added_by":"auto","created_at":"2025-10-17 11:45:34","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":19308,"visible":true,"origin":"","legend":"\u003cp\u003ePotentiodynamic curves of Ni and Ni/h-BN composite coatings in 3.5 wt% NaCl solution.\u003c/p\u003e","description":"","filename":"floatimage6.png","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/2993871d7a5da6ed7384569a.png"},{"id":94823068,"identity":"1b93a900-9e66-4ef8-9c37-ec3d71fc691d","added_by":"auto","created_at":"2025-10-31 06:46:03","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2212803,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7241823/v1/f6f13cf6-3fb9-4cb9-b6a4-157f95f5f6dc.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Structure, Microhardness and Corrosion Properties of the Electrodeposited Ni-BN Nanocomposites","fulltext":[{"header":"INTRODUCTION","content":"\u003cp\u003eOver the last few decades, many researchers concentrated on the field of material and metallurgy to develop new materials with enhanced properties having low cost and better ecological impacts, one of them is metal matrix nanocomposites (MMNC\u0026rsquo;s) [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e, \u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e]. In recent times MMNC\u0026rsquo;s increased their industrial applications in different areas such as aerospace, automobile, electronic packaging, structural engineering etc. due to their magnificent properties [\u003cspan additionalcitationids=\"CR4\" citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR5\" class=\"CitationRef\"\u003e5\u003c/span\u003e]. Ni is one of the most widely used alloying metals all over the world due to its better wear and corrosion resistance. Ni and its compounds can be used in a vast amount of coating, which have good thermal and electrical conductance, high strength, corrosion resistance, good reflection of light. Ni based composite materials are commonly used in aerospace, military, health care, construction, instrumentation, marine, petroleum and biochemical industries [\u003cspan citationid=\"CR6\" class=\"CitationRef\"\u003e6\u003c/span\u003e, \u003cspan citationid=\"CR7\" class=\"CitationRef\"\u003e7\u003c/span\u003e]. Ni matrix composite can be prepared by different types of methods with low cost, good reproducibility and reduced energy consumption. Many researches shows that thin film of other element coated with Ni up to few nanometres have same hardness as bulk nickel. By this process great improvement in electro mechanical system devices can be achieved by Ni coating.\u003c/p\u003e\u003cp\u003eElectrodeposition, also called as electroplating, is defined as the electrochemical process where an electroplated coating is formed on the substrate surface by reducing metal ion from an electrolyte [\u003cspan citationid=\"CR8\" class=\"CitationRef\"\u003e8\u003c/span\u003e, \u003cspan citationid=\"CR9\" class=\"CitationRef\"\u003e9\u003c/span\u003e]. Among the other techniques for preparing MMNC\u0026rsquo;s, electrodeposition is found to be beneficial in improving several functional properties such as precised control over shape, structure and thickness of the electroplated deposits [\u003cspan citationid=\"CR10\" class=\"CitationRef\"\u003e10\u003c/span\u003e]. By conventional choice of operation conditions and bath composition, the properties of the deposits can be modified as per specific applications [\u003cspan additionalcitationids=\"CR12\" citationid=\"CR11\" class=\"CitationRef\"\u003e11\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR13\" class=\"CitationRef\"\u003e13\u003c/span\u003e].\u003c/p\u003e\u003cp\u003eComposite electrodeposition is the method of incorporating the other element grains into the metal matrix during the electrodeposition process. Nitrides such as AlN, TiN, BN, carbides such as SiC, B\u003csub\u003e4\u003c/sub\u003eC, nanorods, nanotubes etc. are commonly used as reinforcement. Introduction of nano reinforced particle in to metallic matrix was found beneficial in improving several functional properties like as surface hardness, surface morphology, corrosion resistance, wear resistance, electrical and magnetic properties [\u003cspan citationid=\"CR14\" class=\"CitationRef\"\u003e14\u003c/span\u003e]. Several times, it also alters the structural parameters of the metallic matrix because of incorporation of impurities and additives for example lattice parameter, grains size and strain, internal stresses (residual stresses), deposition rate, electrolyte composition and pH, crystal orientation (texture), phase formation and solid solution effects [\u003cspan citationid=\"CR15\" class=\"CitationRef\"\u003e15\u003c/span\u003e]. Hardness of nanocomposites was found to be increased by a significant amount than that of the pure metal.\u003c/p\u003e\u003cp\u003eBN is a white, soft, lubricious powder and exists in various form including hexagonal, cubic, and wurtzite phases, each form have their distinct properties. Boron nitride, a 2D material, shares a similar structure and lattice constants with graphene. The layer consists of sp\u003csup\u003e2\u003c/sup\u003e covalent bonds between boron and nitrogen atoms, while between the layers weak Van der Waals interactions exist. Its use in catalysis is primarily attributed to its chemical and thermal stability, as well as its excellent thermal conductivity [\u003cspan additionalcitationids=\"CR17\" citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e\u0026ndash;\u003cspan citationid=\"CR18\" class=\"CitationRef\"\u003e18\u003c/span\u003e]. Recently, h-BN has been identified as a catalyst or co-catalyst, capable of forming heterogeneous structures with other substances, facilitating cooperative catalysis and enhancing the catalytic performance of the system. BN possesses electrical insulating properties, high dielectric breakdown strength, exceptional thermal conductivity, high volume resistivity (10\u003csup\u003e8\u003c/sup\u003e \u0026minus;\u0026thinsp;10\u003csup\u003e13\u003c/sup\u003eohm cm), and maintains excellent chemical stability at high temperature [\u003cspan citationid=\"CR19\" class=\"CitationRef\"\u003e19\u003c/span\u003e, \u003cspan citationid=\"CR20\" class=\"CitationRef\"\u003e20\u003c/span\u003e]. There are many researches where incorporation of BN into nickel matrix has been performed and results of polarization studies shown that corrosion resistance of the coatings has been enhanced because of barrier effect of incorporated BN particles, in contrast with pure Ni. Gyawal et. al. have described that the corrosion resistance of BN incorporated Ni composite is increased about 12 times than Ni coating. Enhanced incorporation of boron nitride in the nickel matrix was found to improve hardness and wear resistance, regardless of boron nitride is soft [\u003cspan citationid=\"CR21\" class=\"CitationRef\"\u003e21\u003c/span\u003e].\u003c/p\u003e\u003cp\u003eHowever, co-deposition of different ceramic particles has been studied by several researchers but co-deposition of boron nitride in nickel matrix and its effects on the structural features and functional properties like microhardness and corrosion resistance have not been well studied yet. Ni/BN could be a good candidate for an improved corrosion resistance and hardness. The aim of the present study was to synthesize BN incorporated nickel matrix nanocomposite coatings by electrodeposition method and to examine its effect on the microstructure, microhardness, surface morphology and electrochemical corrosion properties of the coatings. In addition, attempts will be made to explain composition property relationship for precise tailoring of the properties having smooth, compact, pore, gap and crack free surface.\u003c/p\u003e"},{"header":"EXPERIMENTAL","content":"\u003cp\u003eNi-BN nanocomposites were deposited on commercial grade copper cathode (substrate) from an additive free bath using 100 g/L nickel sulphate and boron nitrite (Sigma Aldrich) and 30gm/L boric acid in ethylene glycol. Chemicals were analytically grade and used as received. Commercial grade copper plates were used as cathode having dimension of 2.0 cm x 1.0 cm x 0.1 cm. Initially, the cathode was mechanically polished using different grades (1/0, 2/0, 3/0 and 4/0) of emery paper for obtaining scratch free and smooth surface. Finally, disc polishing on the fine quality sylbeth cloth with few drops of Grade II Alumina Polishing solution (Geologists Syndicate Pvt. Ltd., India) was used to obtain stain free, reflective and smooth surface. For degreasing of the Cu strips they were immersed in acetone for five minutes and then gently washed with distilled water.\u003c/p\u003e\u003cp\u003eAfter polishing, copper cathode was positioned between the two parallel rectangular anodes of pure nickel. 100 mL of plating solution in a glass cell (450 mL capacity) was utilized as the electrolysis cell. Homogeneous suspension of boron nitride nano-particles in the plating bath was maintained by making a slurry of particles in small amount of solvent and transferring it to appropriate amount of solvent and then by magnetic stirring for 8 hours. The stability of suspension in the bath during electroplating was maintained by continuous magnetic stirring. To get coatings with constant thickness, electro-co-deposition was performed at varying current densities and plating time at 35̊C. Optimum electroplating condition was accomplished by changing one plating parameter once and keeping all the others to a fixed value.\u003c/p\u003e\u003cp\u003eAfter electrodeposition, the surface of cathode was cleaned ultrasonically for 05 minutes. The crystal structure of the Ni/BN composite coatings was analyzed using powder X-ray diffraction (p-XRD) with a Bruker D2-PHASER, benchtop X-ray diffractometer, employing CuKα radiation (λ\u0026thinsp;=\u0026thinsp;1.541836 \u0026Aring;) over a 2θ range of 10\u0026deg;\u0026ndash;90\u0026deg;. Lattice strain and crystallite size were determined from the most intense diffraction peak. Crystallite size (D) of the coatings was calculated using the formula D\u0026thinsp;=\u0026thinsp;λ/βcosθ, and the strain (η) using η\u0026thinsp;=\u0026thinsp;β/4tanθ, where θ is the corresponding Bragg angle and β is the integral breadth.\u003c/p\u003e\u003cp\u003eSurface morphological features and chemical constituents of the deposits were examined via scanning electron microscopy (W-SEM, JEOL, JSM6010LA) equipped with an energy-dispersive X-ray analyzer (EDAX). Elemental composition results, reported in the weight percent (wt%), represent the average of four to six measurements. Corrosion studies were performed with the help of potentiostat coupled with impedance unit (PalmSens, EmStat4s) in a solution of neutral 3.5% NaCl. The Tafel curves for corrosion characterization were recorded at the potential range from \u0026minus;\u0026thinsp;0.5 to +\u0026thinsp;1.0 V vs SCE. Microhardness (Hv in Kgf mm\u003csup\u003e\u0026minus;\u0026thinsp;2\u003c/sup\u003e) measurement of the deposits was performed using digital Vickers microhardness tester (Fine Testing Instruments, India, Model: HVD-100 MT) at 10 gram applied load for 10 seconds. To avoid any substrate effect, average of 10 measurements were taken to get final values.\u003c/p\u003e"},{"header":"RESULTS AND DISCUSSION","content":"\u003cdiv id=\"Sec4\" class=\"Section2\"\u003e\u003ch2\u003eX \u0026ndash; ray diffraction Studies:\u003c/h2\u003e\u003cp\u003e\u003c/p\u003e\u003cp\u003ePowder XRD technique was used to determine the phase and crystalline size of the Ni and Ni/BN nanocomposite coating at various current densities. The characteristics XRD peak of nickel deposited at 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e and 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e and Ni-BN deposited at 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e and 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e are presented in the Fig.\u0026nbsp;\u003cspan refid=\"Fig1\" class=\"InternalRef\"\u003e1\u003c/span\u003e. A gradual change in the intensities of peak with current density clearly indicates that the deposition current density plays a very significant role in structural properties and composition of the coating. Relative texture coefficient (RTC) was calculated to analyse the orientation of crystallites. XRD patterns of the Ni particles exhibit typical intense lines appearing at 2θ\u0026thinsp;=\u0026thinsp;44.17(111), 51.67(200) at current density 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e and 2θ\u0026thinsp;=\u0026thinsp;44.12(111), 51.57(200), 76.28(220) at current density 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e. Ni-BN composite shows intense line at 2θ\u0026thinsp;=\u0026thinsp;44.51(111), 51.76(200), 76.18(220) at current density 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e and 2θ\u0026thinsp;=\u0026thinsp;44.46(111), 51.81(200), 76.57(220) at current density 1.5 Adm\u003csup\u003e\u0026minus;\u0026thinsp;2\u003c/sup\u003e. Texture coefficient calculation of nickel deposit at 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e indicated (200) plane as the predominant orientations and changed to (220) plane as the current density increases to 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e (Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e). Preferred orientation of Ni-BN composites was (220) plane for current densities 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e and as the current density increases preferred orientation shifted to (200) planes at 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e (Table\u0026nbsp;\u003cspan refid=\"Tab1\" class=\"InternalRef\"\u003e1\u003c/span\u003e). From the presented curves of XRD it was analysed that at current density 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e, the preferred orientation of composite after reinforcement of BN in Ni composite shift from (200) to (220). Grain size of nickel was 27.6 nm at current density of 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e whereas it was found to be 16.2 nm for 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e. The result confirmed the formation of fine-grained deposits when the current density enhances. After the reinforcement of BN in Ni composite there is significant change in crystallite size was observed and it was observed to be 22.5 nm and 16.77 for current density 0.5 and 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e respectively. A decrease in grain size indicates the grain refinement as well as fine reinforcement of BN particles in Ni matrix. A raise in current density leads to a higher over potential, which boosts the rate of nucleation and consequently promotes refinement of grains. The co-deposition of BN ceramic particles with the Ni matrix explains the certain peaks disappearance in the XRD data, while the size of grain of the nickel matrix remains unaffected by the presence of BN particles at higher current density. In all XRD analysis of Ni-BN coatings, the co-deposition of BN ceramic particles creates additionally nucleation centre, thereby inhibiting crystal growth. Pompei et. al. reported that incorporation of BN particles in the nickel matrix favours the loss of orientation of pure Ni deposits [\u003cspan citationid=\"CR22\" class=\"CitationRef\"\u003e22\u003c/span\u003e]. Also, BN particle incorporation does not affect the grain size of metal matrix. It has been also reported that co-deposition of fine ceramic particles with metals leads to reduction in grain size. This is because of the inhibition of normal growth of grain and the promotion of new nucleation sites induced by the particles of second-phase as seen at lower current density in present study. The Ni-BN phase provides lattice parameter between 3.525\u0026Aring; to 3.534 \u0026Aring; which is slightly higher compared to the pure nickel standard value (3.517\u0026Aring;). Lattice strain of all the coatings was observed very small (0.00248 to 0.005456). The calculated strain of the nanocomposite coatings are low, which can be ascribed to the reduced deformation caused by ceramic particles, as they are in a closely strain-relaxed state. Other than Ni and Ni-BN matrix no peak was found there in the XRD patterns which indicate that the composites have not gone through any phase transition within the given temperature range.\u003c/p\u003e\u003cp\u003e\u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e\u003ccaption language=\"En\"\u003e\u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e\u003cdiv class=\"CaptionContent\"\u003e\u003cp\u003eCrystallite size, strain and relative texture coefficients of nickel and Ni-BN coatings at different current densities.\u003c/p\u003e\u003c/div\u003e\u003c/caption\u003e\u003ccolgroup cols=\"5\"\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e\u003cdiv align=\"left\" class=\"colspec\" colname=\"c5\" colnum=\"5\"\u003e\u003c/div\u003e\u003cthead\u003e\u003ctr\u003e\u003cth align=\"left\" colname=\"c1\"\u003e\u003cp\u003eComposite\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c2\"\u003e\u003cp\u003eCurrent density\u003c/p\u003e\u003cp\u003eA/dm\u003csup\u003e2\u003c/sup\u003e\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c3\"\u003e\u003cp\u003eCrystallite size\u003c/p\u003e\u003cp\u003e(nm)\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c4\"\u003e\u003cp\u003eStrain\u003c/p\u003e\u003c/th\u003e\u003cth align=\"left\" colname=\"c5\"\u003e\u003cp\u003eRelative texture coefficient\u003c/p\u003e\u003cp\u003e(111) (200) (220)\u003c/p\u003e\u003c/th\u003e\u003c/tr\u003e\u003c/thead\u003e\u003ctbody\u003e\u003ctr\u003e\u003ctd align=\"left\" colname=\"c1\"\u003e\u003cp\u003eNi\u003c/p\u003e\u003cp\u003eNi\u003c/p\u003e\u003cp\u003eNi-BN\u003c/p\u003e\u003cp\u003eNi-BN\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c2\"\u003e\u003cp\u003e0.5\u003c/p\u003e\u003cp\u003e1.5\u003c/p\u003e\u003cp\u003e0.5\u003c/p\u003e\u003cp\u003e1.5\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c3\"\u003e\u003cp\u003e27.6\u003c/p\u003e\u003cp\u003e16.2\u003c/p\u003e\u003cp\u003e22.5\u003c/p\u003e\u003cp\u003e16.8\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c4\"\u003e\u003cp\u003e0.003239\u003c/p\u003e\u003cp\u003e0.004893\u003c/p\u003e\u003cp\u003e0.003534\u003c/p\u003e\u003cp\u003e0.004733\u003c/p\u003e\u003c/td\u003e\u003ctd align=\"left\" colname=\"c5\"\u003e\u003cp\u003e0.06 0.94 ---\u003c/p\u003e\u003cp\u003e0.07 0.20 0.72\u003c/p\u003e\u003cp\u003e0.31 0.49 0.19\u003c/p\u003e\u003cp\u003e0.06 0.09 0.98\u003c/p\u003e\u003c/td\u003e\u003c/tr\u003e\u003c/tbody\u003e\u003c/colgroup\u003e\u003c/table\u003e\u003c/div\u003e\u003c/p\u003e\u003c/div\u003e\n\u003ch3\u003eEffect of current density on wt% incorporation of BN in nickel matrix:\u003c/h3\u003e\n\u003cp\u003e\u003c/p\u003e\u003cp\u003eCurrent density is extremely widely considered parameter in the electrodeposition process. Changes in current density range of 0.5 to 2.5 A/dm\u003csup\u003e2\u003c/sup\u003e influenced the quality of the deposits, with the best quality achieved at current densities between 0.5 to and 1.0 A/dm\u003csup\u003e2\u003c/sup\u003e. For enhanced current densities, deposit quality declined, leading to blunt deposits and effects of burning at the edges of the deposited plates. Figure illustrates the correlation of current density and the BN content in the Ni-BN deposits. As current density increased from 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e to 2.5 A/dm\u003csup\u003e2\u003c/sup\u003e, the content of BN in the deposits at first increased to 5.1% on current density 1.0 A/dm\u003csup\u003e2\u003c/sup\u003e and after that gradually decrease to 3.6% as current density increased to 2.5 A/dm\u003csup\u003e2\u003c/sup\u003e. The variation in BN particle with respect to current density in the alloy composite is believed to be influenced by the availability of BN particles at the cathode surface, the discharge of ions through current density and the enmeshment of particles in the producing alloy. Tripathi et. al. reported that BN content incorporation in coating firstly increased with enhancement in current density, then reached up to maximum, thereafter followed a sharp decrease as current density increases [\u003cspan citationid=\"CR23\" class=\"CitationRef\"\u003e23\u003c/span\u003e]. It is assumed that Metal ions adsorb onto the surface of particle, so the rate of particle incorporation is directly related to the rate of metal deposition.\u003c/p\u003e\u003cp\u003eHowever, metal deposition rate, which remains kinetically controlled, continued to increase with current density, causing a tremendous decline in content of BN particles. The phased decrease in content of particles beyond one can be attributed to diffusion control with metal and discharge occurring under a mixed kinetic and diffusion control regime. The decrease in boron nitride particle content beyond a specific current density may be attributed to transition from kinetic control to diffusion controlled. As the particle reinforcement process become diffusion controlled, its rate stayed constant despise of increase in current density.\u003c/p\u003e\n\u003ch3\u003eMicrohardness Studies:\u003c/h3\u003e\n\u003cp\u003e\u003c/p\u003e\u003cp\u003eMicrohardness of Nickel and Ni-BN nanocomposite coatings were calculated by Vicker\u0026rsquo;s microhardness test. The pure Nickel coating without any reinforcement deposited at current density 0.5A/dm\u003csup\u003e2\u003c/sup\u003e has hardness of 273 HV. Further it increased to 334HV when current density enhances to 1.5 A/dm\u003csup\u003e2\u003c/sup\u003e and after that as the current density enhances the microhardness of the deposits decreases gradually up to 267HV at current density 3.0 A/dm\u003csup\u003e2\u003c/sup\u003e.The Addition of BN to the nickel matrix raises the microhardness to about 332 HV at current density 0.5 A/dm\u003csup\u003e2\u003c/sup\u003e which further increased to 415HV at current density 1.0 A/dm\u003csup\u003e2\u003c/sup\u003e and then gradually decreases as the current density increases.\u003c/p\u003e\u003cp\u003eAt current density 1.0A/dm\u003csup\u003e2\u003c/sup\u003e, the Ni-BN composite has significantly higher hardness than the pure nickel coating. This could be because of dispersion strengthening from the integrated BN particle into the matrix metal. Li et. al. reported that the incorporation of BN in Ni-W alloy clearly shows that the cross-section microhardness of coating increases towards the surface[\u003cspan citationid=\"CR16\" class=\"CitationRef\"\u003e16\u003c/span\u003e]. Paydar et. al. reported that incorporation of Boron nitride and Boron carbide into Ni matrix show the increment in microhardness as there is increase in current density[\u003cspan citationid=\"CR24\" class=\"CitationRef\"\u003e24\u003c/span\u003e]. The reduction in hardness after reaching the maximum value follows a pattern similar to that of the particle content of the composites. The trend of hardness with change in current density indicates that hardness is dependent on size of crystallite. The improvement in micro hardness of the Ni/BN coating can be ascribed to (a) the dispersive strengthening effect of BN, (b) the restriction of crystalline bulk growth by BN nanosheets during electrodeposition, which refines the nickel crystallites,(c) the packing of grain boundary and dislocation motion in the Nickel matrix by the BN nanosheets. A lesser crystallite size means a higher grain boundaries number, which hinder motion of dislocation, resulting in harder materials. The uniform distribution of boron nitride particles in the coatings likely results in a high number of particles located at the grain boundaries, which obstruct dislocation movement and prevent dislocation slip, thereby increasing the hardness of the deposits.\u003c/p\u003e\n\u003ch3\u003eSurface Morphology:\u003c/h3\u003e\n\u003cp\u003e\u003c/p\u003e\u003cp\u003e\u003c/p\u003e\u003cp\u003eThe surface morphology of incorporated boron nitride in nickel composite coating was analysed by scanning electron microscope (SEM) at various magnification. Figures\u0026nbsp;\u003cspan refid=\"Fig4\" class=\"InternalRef\"\u003e4\u003c/span\u003e and \u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e displays surface morphologies of Ni and the Ni/BN nanocomposite coatings, respectively. The electrodeposited composite coating clearly exhibits a surface which is smooth and have finer grains compared to the Ni coating. Previous studies have reported that codeposition of fine ceramic particles within a Ni metal matrix leads to grain size reduction, primarily due to the repression of normal growth of grain and the promotion of nucleation facilitated by the presence of second-phase particles. As shown in Fig.\u0026nbsp;\u003cspan refid=\"Fig5\" class=\"InternalRef\"\u003e5\u003c/span\u003e, BN particles were successfully co-deposited into the Ni matrix, as indicated by the dark voids observed in the image. The incorporation of BN ceramic particles significantly influences the structural and morphological characteristics of the Ni matrix. The SEM image exhibits that the entire electrodeposited metal matrix has fine granular structure with uniform grain distribution. The interface between boron particle and matrix phase is very small and thus cannot be clearly distinguished. However, it is evident from the SEM images that the crystal grains on the surface of the composite layer are smooth and evenly distributed. Li et.al. reported that incorporation of Boron Nitride in Ni-Co alloy shows that there is no obvious gap and pores on the surface [\u003cspan citationid=\"CR25\" class=\"CitationRef\"\u003e25\u003c/span\u003e]. The Spherical Convex structures were smooth and compact and as the current density varied, the gaps between the large convex structures gradually disappeared, leading to improved compactness in the micro-nanostructure of the coating. However, EDAX analysis shows uniform distribution of the BN particle into metallic matrix. All the nanocomposite coatings were observed to be free of cracks and pores having closely smooth surface.\u003c/p\u003e\u003cdiv id=\"Sec8\" class=\"Section2\"\u003e\u003ch2\u003eCorrosion Studies:\u003c/h2\u003e\u003cp\u003e\u003c/p\u003e\u003cp\u003eThe corrosion behaviour of Ni and Ni/h-BN composite coatings was studied by monitoring after immersion in a neutral 3.5 wt% solution of NaCl until it stabilized. The polarization curves for both nickel and Ni/BN nanocomposites at various current densities are presented in Fig.\u0026nbsp;\u003cspan refid=\"Fig6\" class=\"InternalRef\"\u003e6\u003c/span\u003e. Pure nickel deposits exhibits a slight active-passive transition. In contrast, BN incorporated Ni/BN composite coatings display an extensive passive region as well as a significant positive shifting of corrosion potentials compared to Ni. These results clearly indicate that the reinforcement of BN into the metal matrix improves corrosion protection. Specifically, in the 3.5 wt% solution of NaCl, the corrosion potential of the Ni/BN nanocomposite increases with enhancement in current density from 1.0 to 2.0 A/dm\u003csup\u003e2\u003c/sup\u003e. The reduced corrosion rate of the Ni/BN composite coatings can be ascribed to both compact metallic matrix and the incorporated BN particles, which inherently provide improved corrosion resistance. Hsu et. al. found that for the Ni-P/BN composites the corrosion resistance improves significantly which is caused by barrier effect of boron nitride particles, compared to standard Ni-P coatings [\u003cspan citationid=\"CR26\" class=\"CitationRef\"\u003e26\u003c/span\u003e]. Similar analysis was also reported by Li et.al. for the incorporation of BN in Ni-Co alloy coating [\u003cspan citationid=\"CR25\" class=\"CitationRef\"\u003e25\u003c/span\u003e]. Furthermore, the structural modification of nickel crystallites, evidenced by changes in preferred orientation upon nanoparticle incorporation, contributes to improved corrosion resistance. Another possible explanation for the lower corrosion rate lies in the electrochemical mechanism [\u003cspan citationid=\"CR27\" class=\"CitationRef\"\u003e27\u003c/span\u003e]. Previous studies have shown that dispersing ceramic nanoparticles in nickel matrix, materials with positive standard potential more than nickel creates corrosion microcells, where the ceramic nanoparticles act as cathodes and nickel as anode. It promotes anode polarization, which may explain the enhanced corrosion resistance observed in Ni/BN composite coating.\u003c/p\u003e\u003c/div\u003e"},{"header":"Conclusions","content":"\u003cp\u003eIn this study, Ni/BN nanocomposite coatings were successfully synthesized on copper plate by electrodeposition technique using an ethylene glycol-based electrolyte. The effects of BN incorporation and varying current densities on the mechanical, structural, and electrochemical properties of coatings were systematically examined. XRD analysis confirmed the formation of nanocrystalline structures with a change in preferred orientation and significant grain refinement due to the incorporation of BN particles. The crystallite size decreased with increasing current density, indicating enhanced nucleation and inhibited grain growth improved by the reinforcement of BN. The co-deposition of BN did not induce any new phase formation but changed the lattice parameters slightly, showing a strain-relaxed and stable composite structure.\u003c/p\u003e\u003cp\u003eSEM imaging analysis observed that the Ni/BN coatings possessed smoother, denser, and more uniform surfaces equated to Ni coatings. The coatings were free from cracks and voids. Microhardness testing shows that the reinforcement of boron nitride significantly improved the microhardness of the Ni metal matrix, reaching a peak value of 415 HV at current density of 1.0 A/dm\u0026sup2;. This improvement is attributed to grain refinement, dispersion strengthening, and the inhibition or blocking of dislocation movement by the embedded ceramic particles. Electrochemical corrosion tests in 3.5 wt% solution of NaCl demonstrated enhanced corrosion resistance of the incorporated BN in Ni coatings compared to pure Ni, as evidenced by a positive shift in corrosion potential and lower corrosion current density. The improved corrosion behaviour is primarily due to the BN particles shows barrier effect and the formation of a sturdy passive layer on the coating surface.\u003c/p\u003e\u003cp\u003eOverall, the results confirm that BN incorporation in nickel coatings via electrodeposition leads to significant improvements in both mechanical and corrosion-resistant properties. This makes Ni/BN nanocomposite coatings highly suitable for demanding applications in aerospace, marine, and industrial environments where durability and corrosion protection are critical.\u003c/p\u003e"},{"header":"Declarations","content":"\u003cp\u003e\u003cstrong\u003eCompeting interests\u003c/strong\u003e\u003cp\u003eThe authors declare no competing interests.\u003c/p\u003e\u003c/p\u003e\u003cp\u003e\u003ch2\u003eEthical approval and consent to participate\u003c/h2\u003e\u003cp\u003eNot applicable.\u003c/p\u003e\u003c/p\u003e\u003cp\u003e\u003cstrong\u003eConsent to publish\u003c/strong\u003e\u003cp\u003eNot applicable.\u003c/p\u003e\u003c/p\u003e\u003ch2\u003eFunding Statement\u003c/h2\u003e\u003cp\u003eThe authors acknowledge the funding from the Science and Engineering Research Board (File No. EEQ/2022/000530), New Delhi, India and University Grant Commission (F.30\u0026ndash;505/2020-BSR), New Delhi, India.\u003c/p\u003e\u003ch2\u003eAuthor Contribution\u003c/h2\u003e\u003cp\u003eRS: conducted the research and characterization, AS: original draft righting, mechanical property study, AKC: conceptualization, methodology, data curation, review and editing, RK: analysis and contributed in preparing tables and figures, ES: corrosion study, PKR: optimization of plating bath, review and editing.\u003c/p\u003e\u003ch2\u003eData Availability\u003c/h2\u003e\u003cp\u003eThe datasets generated and analysed during the current study are available from the corresponding author on reasonable request.\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\u003cli\u003e\u003cspan\u003e-Malaki M, Tehrani AF, Niroumand B. 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Discover Electrochem. 2025;2(1):8. \u003cspan class=\"ExternalRef\"\u003e\u003cspan class=\"RefSource\"\u003ehttps://doi.org/10.1007/s44373-025-00022-0\u003c/span\u003e\u003cspan address=\"10.1007/s44373-025-00022-0\" targettype=\"DOI\" class=\"RefTarget\"\u003e\u003c/span\u003e\u003c/span\u003e.\u003c/span\u003e\u003c/li\u003e\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"","lastPublishedDoi":"10.21203/rs.3.rs-7241823/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7241823/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study investigates the co-deposition, characterization and applications of nickel/boron nitride (Ni/BN) nanocomposites prepared by electrodeposition on copper plate from an ethylene glycol-based electrolyte. The main objective was to evaluate the impact of boron nitride (h-BN) incorporation on the corrosion resistance, surface morphology, microstructure and microhardness of the nickel matrix. Powder X-ray diffraction (p-XRD) analysis shows the layout of nanocrystalline coatings with grain refinement observed upon BN incorporation. A shift in preferred orientation and lattice strain indicated successful particle incorporation without phase transformation. Scanning electron microscopy (SEM) shows that Ni/BN coatings manifest finer, smoother, and more compact surface morphologies than pure Ni coatings. Vickers microhardness testing showed a significant increase in hardness with BN addition, reaching maxima of 415 HV at 1.0 A/dm\u0026sup2; because of dispersion strengthening and grain boundary pinning effects. Potentiodynamic polarization analysis in 3.5 wt% solution of NaCl demonstrated enhanced corrosion resistance of the Ni/BN nanocomposite coatings compared to Ni, attributed to the barrier effect of uniformly distributed BN nanosheets and enhanced passive film stability. The results suggest that electrodeposited Ni/BN nanocomposites are better materials for applications requiring improved mechanical strength and corrosion resistance.\u003c/p\u003e","manuscriptTitle":"Structure, Microhardness and Corrosion Properties of the Electrodeposited Ni-BN Nanocomposites","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-17 11:37:29","doi":"10.21203/rs.3.rs-7241823/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"49f7bec8-dad7-44f2-a570-7c953f4f1121","owner":[],"postedDate":"October 17th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-10-30T09:09:06+00:00","versionOfRecord":[],"versionCreatedAt":"2025-10-17 11:37:29","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7241823","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7241823","identity":"rs-7241823","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}