Electrodeposition of Ni matrix composite coatings with embedded CrAlY particles

An electrolytic sediment codeposition process was employed to fabricate composite coatings containing CrAlY particles embedded in an Ni matrix. The effects of three main deposition parameters and their interactions on the amount of CrAlY particles incorporated in the composite coating were investigated using a design of experiments (DoEs) method. Current density, agitation rate and concentration of CrAlY particles in the solution were the parameters considered in the 2(3) full factorial design. With different combinations of the deposition parameters, the amount of CrAlY particles in the composite coatings ranged from 20 to 49 vol.-%. The DoE results show that the agitation rate exhibited the greatest influence on the amount of CrAlY particles incorporated in the composite coating, followed by the interaction between agitation and particle loading and then the particle loading itself. Current density did not appear to affect the particle incorporation for the present set-up.