Key Takeaways & Executive Findings
- •• Carbon-sol-reinforced Cu composite coatings were successfully fabricated via electrodeposition, achieving uniform dispersion of carbon particles and enhanced coating quality. • The optimal addition of 20 mL/L carbon sol significantly improved coating thickness, density, and uniformity, leading to superior wear and corrosion resistance. • The Cu-CS composite coating exhibited a low wear volume (1.15 × 10−3 mm3), high hardness (HV0.5 137.1), and low corrosion rate (0.191 mm/a), attributed to strengthening and lubricating effects of carbon particles. • Excessive carbon sol content compromises the microstructure, creating defects that undermine coating performance, highlighting the importance of optimizing reinforcement concentration.
Abstract
This study successfully developed a series of carbon-sol-reinforced copper (Cu-CS) composite coatings by electrodeposition employing a superiorly dispersed carbon sol (CS) to avoid nanoparticle aggregation. The CS, characterized using transmission electron microscopy and zeta potential analysis, consisted of carbon particles with an approximate diameter of 300 nm uniformly distributed in the electrolytes. The characteristics of the composite coatings were examined via scanning electron microscopy to observe its microstructures, X-ray diffraction to detect its phase constituents, and durability testing to determine the wear and corrosion resistance. Results indicated a significant improvement in coating thickness, density, and uniformity achieved for the Cu-CS composite coating with the addition of 20 mL/L CS. Moreover, the Cu-CS composite coating exhibited a low wear volume (1.15 × 10−3 mm3), a high hardness (HV0.5 137.1), and a low corrosion rate (0.191 mm/a). The significant contribution of carbon particles to the improvement of coating performance is mainly influenced by two factors, namely, the strengthening and lubricating effects resulting from the incorporated carbon particles. Nevertheless, overdosage of CS can compromise the microstructure of the Cu-CS composite coating, creating defects and undermining its functionality.
1. Introduction
Copper (Cu) and its alloys [1–3] play an indispensable role in various industries, including the aerospace, transportation, and construction sectors, because of their good electrical conductivity [4–5] and ductility [6]. Electrodeposition technology [7–9] is also widely used in the preparation of Cu coatings because of its good controllability and the fact that the coatings prepared by this method are characterized by good bonding, denseness, and homogeneity. However, the inherently poor wear resistance of Cu often results in its malfunction because of surface degradation during operational usage. Cu-based composite coatings, doped with different reinforcing phases, not only retain the intrinsically superior properties of the Cu coatings but also endow the composites with unique mechanical characteristics [10–14].
Research has consistently illustrated substantial improvements in the comprehensive properties of the reinforced composite coatings [15–17]. For instance, Budi et al. [18] employed electrodeposition to construct Ni–TiN/Si3N4 composite coatings possessing superb wear resistance. Mirsaeedghazi et al. [19] developed Cu/SiC and Cu/SiC/graphite composite coatings using pulsed current electrodeposition and determined that the addition of graphite effectively reduced the wear rate of the prepared coatings. Ovchinnikova et al. [20] produced Ni–Co–Al2O3 composite coatings with exceptional wear resistance based on low-chloride electrolytes.
In recent research, scholars have revealed that carbon materials can function as potent reinforcement agents to substantially augment the wear resistance and other properties of composite coatings because of their exceptional strength, thermal stability, self-lubrication, and chemical stability [21–23]. Wu et al. [24] explored the comprehensive performance of Ni–P–GO coatings reinforced with graphene oxide (GO), revealing a proportional relationship between GO content and friction resistance of the coating. However, excessive concentrations of GO led to a decrease in coating performance; the composite coating exhibited maximum hardness and optimal wear resistance at a GO concentration of 40 mg/L. Zhang et al. [25] employed electrodeposition to fabricate (Ni–Fe)–graphene composite coatings with robust mechanical properties on stainless steel substrates. Luo et al. [26] deposited Ni and Ni/GO composite coatings on the surface of aluminum alloys, and wear tests revealed that the Ni/GO composite coatings exhibited a 21% lower volume wear rate than the Ni coatings. According to the different functions of different forms of carbon materials, their incorporation into coatings as reinforcing phases can improve the performance of the coatings in many fields of application.
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Zhen He, Songlin Zheng, Lei Zhu, Wuxin Yang, Muhammad D. Hayat, Yuxin Wang (2025). Fabrication and performance of carbon-sol-reinforced Cu composite coatings. Int. Journal of Minerals, Metallurgy and Materials (矿物冶金与材料学报). https://doi.org/10.1007/s12613-024-3030-5
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Frequently Asked Questions
What is the main objective of this study?
The main objective is to develop carbon-sol-reinforced copper (Cu-CS) composite coatings via electrodeposition, using a highly dispersed carbon sol to avoid nanoparticle aggregation and to improve the wear and corrosion resistance of copper coatings.
How were the carbon-sol-reinforced Cu composite coatings fabricated?
The coatings were fabricated by electrodeposition from an electrolyte containing a uniformly dispersed carbon sol (CS) with carbon particles of approximately 300 nm diameter. The optimal concentration of CS was found to be 20 mL/L.
What were the key performance improvements observed in the Cu-CS composite coatings?
The Cu-CS composite coatings exhibited significantly improved coating thickness, density, and uniformity. They also showed a low wear volume (1.15 × 10−3 mm3), high hardness (HV0.5 137.1), and low corrosion rate (0.191 mm/a), attributed to the strengthening and lubricating effects of the incorporated carbon particles.
What happens when the carbon sol concentration is excessive?
Excessive carbon sol concentration compromises the microstructure of the Cu-CS composite coating, creating defects that undermine its functionality, such as reduced wear and corrosion resistance.
What are the potential applications of these composite coatings?
These composite coatings can be used in industries requiring durable and corrosion-resistant copper surfaces, such as aerospace, transportation, and construction, where improved wear resistance is critical.
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