Development of Ni-W Electrodeposited Gradient Coatings and Their Application for Industrial Energy Efficiency Optimization

Yun Feng Chang; Tsi Liong Ong

doi:10.4028/p-f5tFti

Paper Titles

Effects of Unidirectional Untreated Tiger Grass Fiber Reinforcement on Tensile Strength and Water Absorption of Epoxy Resin Composites
p.67

Mechanical Characterization of Silicone Rubber with Quail Eggshells as Bio-Based Filler
p.73

Effects of Post-Heat Treatments on Mechanical and Electrical Properties of 6201 Aluminum Alloy
p.81

Effect of Post-Weld Heat Treatment on Microstructure and Mechanical Properties of Friction Stir Welded T-Joint between AA6061 and Steel
p.87

Development of Ni-W Electrodeposited Gradient Coatings and Their Application for Industrial Energy Efficiency Optimization
p.95

Tribological Wear Analysis of Bronze-Alloy for Bearing Application
p.103

Influence of Load Type on the Passivation and Failure of AISI 2205 under Geothermal Corrosion Fatigue Conditions
p.111

Stress Assessment in a TPU Disk under Diametral Compression Relying on Strain Measurements by Localized Spectrum Analysis
p.121

Development of Ultrasonic Pulse Velocity-Based Multi-Stage Model and Field Manual for Early Frost Damage Diagnosis
p.127

HomeAdvances in Science and TechnologyAdvances in Science and Technology Vol. 175Development of Ni-W Electrodeposited Gradient...

Development of Ni-W Electrodeposited Gradient Coatings and Their Application for Industrial Energy Efficiency Optimization

Abstract:

This study investigates the development and application of Ni-W alloy gradient coatings fabricated via electrodeposition as a direct strategy for industrial energy efficiency optimization. An eight-layer graded coating architecture was successfully synthesized on low-carbon steel substrates through a programmed current density sequence (2–16 A/dm²). This approach produced a progressive increase in tungsten content from ~11.3 at.% at the substrate interface to ~21.9 at.% at the surface, achieving a maximum microhardness of 875 HV via combined solid solution strengthening and grain refinement (3.8–12.5 nm). Crucially, the compositional gradient effectively mitigated internal stresses, enabling the deposition of thick (100 µm), crack-free coatings, in contrast to the cracking observed in homogeneous high-W coatings beyond 40 µm. The enhanced durability and surface properties directly address key industrial energy loss mechanisms. Preliminary assessments indicate that the extended component service life can reduce embodied energy consumption for replacements by up to 65%, while the superior surface hardness and lubricity contribute to operational energy savings of 8–15% in transmission systems through friction reduction. These results demonstrate a clear pathway for leveraging advanced surface engineering to achieve significant, quantifiable energy savings in manufacturing operations..