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Applied Surface Science 351 (2015) 889–896

Contents lists available at ScienceDirect

Applied Surface Science


journal homepage: www.elsevier.com/locate/apsusc

Producing cobalt–graphene composite coating by pulse


electrodeposition with excellent wear and corrosion resistance
Cansen Liu, Fenghua Su ∗ , Jizhao Liang
School of Mechanical and Automotive Engineering, South China University of Technology, Wushan Road No. 381, Tianhe District, Guangzhou 510640,
Guangdong Province, China

a r t i c l e i n f o a b s t r a c t

Article history: Cobalt (Co) and graphene oxide/cobalt (GO/Co) composite coatings were fabricated by pulse electrodepo-
Received 30 March 2015 sition technique from an aqueous bath containing cobalt sulfate and GO, etc. Effect of the incorporations of
Received in revised form 21 May 2015 GO on morphology, phase structure, average grain size and corrosion and wear resistance of the resulting
Accepted 4 June 2015
composite coatings were evaluated in detail. Scanning electron microscope (SEM) and energy dispersed
Available online 12 June 2015
X-ray (EDX) show that the GO nanosheets disperse homogeneously in the composite coating and the
incorporations of GO change the morphologies of the deposit from conical shaped structure to protrud-
Keywords:
ing structure. In addition, the co-deposition GO with Co ions favor the formation of hcp (1 0 0), (0 0 2)
Cobalt
Graphene oxide
and (1 0 1) textures in the composite coating and have functions of grain refining and hardness enhance-
Pulse electrodeposition ment. The wear tests show that the incorporations of GO in the coating improve the wear resistance and
Wear friction reduction of the deposit. The electrochemical corrosion tests using potentiodynamic polarization
Corrosion and electrochemical impedance spectroscopy show that the GO/Co composite coating possesses better
corrosion resistance than the pure Co coating.
© 2015 Elsevier B.V. All rights reserved.

1. Introduction resistance and mechanical properties of both hardness and wear


resistance.
Electrodeposition is one of the most important techniques Graphene, a two-dimensional (2D) sp2 -hybridized carbon nano-
for producing coating materials with excellent mechanical and material with a one-atom thick structure, has been recognized as
chemical properties [1,2]. The deposited coatings with excellent one of the most promising carbon materials after fullerenes and
properties can increase the lifetime of components exposed to cor- carbon nanotubes, since its discovery in 2004 by Novoselov and
rosion and wear condition as most of failures such as friction, wear co-workers [9]. Graphene has received extensive attentions for
and corrosion often occur on the material surface. both fundamental and applied researches due to its unique elec-
Nanoparticles are always used to be incorporated in metal and trical, optical, and mechanical properties. Unfortunately, the neat
metal alloy coatings to enhance their mechanical and chemical graphene doesn’t have functional groups on its surface, which harm
properties [3–8]. Aghaie et al. [4] electrodeposited Ni–SiC compos- its dispersibility in the matrix and limits the potential applica-
ites on copper surface and found that increasing the concentration tion for the as-prepared composites or coatings [10,11]. Graphene
of SiC particles in the Watts bath results in the improvement of coat- oxide (GO), as an oxidized derivative of graphene, not only with
ing microhardness and the decrease of the friction coefficient and the excellent properties of neat graphene but also having abundant
wear missing volume. Kasturibai et al. [5] found that the microhard- surface functional groups, are expected to be promising nano-scale
ness and corrosion resistance of Ni–Si3 N4 nanocomposite coating filler for the next generation of functional composite materials
were higher and better than those of the pure Ni coating. Carpen- [12]. Because of its abundant oxygen-containing functional groups,
ter et al. [6] found that the produced Ni-CNTs exhibited superior such as hydroxyl, epoxide, carbonyl, carboxyl, etc., GO possesses
mechanical properties than the pure Ni due to the uniformly dis- good solubility in solvents and provides fertile opportunities for the
persed CNTs in it. Shao et al. [8] revealed that incorporations of construction of GO-based hybrid nanocomposites [13]. Therefore,
TiO2 nanoparticles in Ni coating greatly improved the corrosion the composite coatings with superior properties from the co-
deposition of GO with metal ions can be expected and are feasible.
Recently, some works have been done in studying the application
∗ Corresponding author. Tel.: +86 20 87112341; fax: +86 20 87112341. of GO in nickel (Ni) electrodeposition [14,15]. Kuang et al. [14] pre-
E-mail address: fhsu@scut.edu.cn (F. Su). pared GO/Ni composites by electrodeposition in a nickel sulfamate

http://dx.doi.org/10.1016/j.apsusc.2015.06.018
0169-4332/© 2015 Elsevier B.V. All rights reserved.
890 C. Liu et al. / Applied Surface Science 351 (2015) 889–896

solution with GO sheets in suspension. They demonstrated that the (AFM). The phase structure of GO and the deposited samples were
thermal conductivity and hardness of the composite film were sig- characterized using a Philips X’pert X-ray diffractometer (XRD, Cu-
nificantly improved due to the incorporations of GO nanosheets. K␣ radiation) operating at 40 kV and 40 mA over the 2 range
Kumar et al. [15] found that the Ni–graphene composite coating 5–80◦ . Raman spectra of the GO and GO/Co composite coating
displayed higher corrosion resistance than the bare Ni coating. were obtained using a Dilor Labram-1B multichannel confocal
However, there has no study on the friction and wear property microspectrometer in excitation of 514 nm and 20 mW laser.
of the composite coating in their study. Moreover, cobalt (Co) The morphological characterizations of the Co and GO/Co
coatings exhibited better wear resistance and friction reduction coatings were characterized using a FEI Quanta 200 scanning elec-
than Ni coatings as the considered coatings for the replacement of tron microscope (SEM). The distribution of GO in the composite
hexavalent chromium electrodeposition [16]. The addition of GO coatings were analyzed using the backscattered (BS)-SEM method.
in electroplating Co is expected to produce the GO/Co composite The element mass fraction of the coatings was measured by Energy
coating with superior properties. Dispersed X-ray (EDX) microanalyzer attached with the Quanta
In this work, GO was synthesized using a modified Hummers 200 SEM from the same picture for the surface morphology analy-
method. The Co and GO/Co composite coatings were fabricated by sis. The microhardness was measured on a Vickers microhardness
a pulse electrodeposition technique. Effect of the incorporations tester with a load of 100 g applied for 10 s. Eight measurements
of GO on the microstructure of the composite coatings, including were made for each sample and the average value from the eight
morphology, phase structure, average grain size, was systemically replica tests were reported.
evaluated. In addition, the differences in the hardness, friction and The friction and wear behaviors of the Co and GO/Co composite
wear behavior, and the corrosion resistance of the Co and GO/Co coatings sliding against GCr15 steel ball with diameter of 4.0 mm
coatings were comparatively studied. were tested on a ball-on-disk tribometer under dry sliding condi-
tions at room temperature and ambient humidity. The tests were
2. Experimental performed under sliding speed of 0.267 m s−1 and load of 2.0 N for
30 min. The diameters of wear tracks on coating were 15.0 mm.
2.1. Preparation of graphene oxide (GO) After the wear tests, line profiles of the wear tracks were mea-
sured using the surface profile measurement system (BMT Expert
In this study, GO was synthesized from natural graphite powder 3D, Germany). The width and depth of the wear track were con-
by means of a modified Hummers method [17,18]. Typically, 10 g verted into wear volume by the equipment software automatically.
graphite powder and 8 g NaNO3 were added to 250 mL cooled (0 ◦ C) The wear rates of all the coatings were calculated from K = V/S × F,
concentrated H2 SO4 . 35 g of KMnO4 was added gradually with cool- where V is the wear volume (mm3 ), S the total sliding distance (m)
ing and stirring, to make sure the temperature of the mixture below and F the normal load (N). Three replicate friction and wear tests
20 ◦ C. Then, the mixture was stirred at 35 ◦ C for 40 min. After that, were carried out for each specimen and the average was reported
450 mL distilled water was slowly added to the mixture, resulting with their errors. After sliding, the wear surfaces of the coatings
in the temperature increasing to 98 ◦ C. And, the mixture was kept were analyzed using the Quanta 200 SEM.
at this temperature for 15 min. To terminate the reaction, 1.2 L dis- Electrochemical corrosion test was carried out in a three elec-
tilled water and 20 mL 30% H2 O2 were added one by one. The solid trode cell. A platinum plate and saturated silver/silver chloride
product was collected by centrifugation and washed repeatedly by (Ag/AgCl) electrode were used as the counter and reference elec-
5% HCl solution until no sulfate could be detected by BaCl2 . Finally, trode, respectively. The as-deposited Co and GO/Co composite
the product of GO was dried in a vacuum oven at 60 ◦ C for 24 h. coatings were used as the working electrode. Measurements were
performed by an electrochemical workstation (CorrTest CS310,
2.2. Electrodeposition of Co and GO/Co composite coatings Wuhan Corr Test Instrument Co. Ltd., China) in a free-aerated
3.5 wt.% NaCl solution at room temperature. Before electrochem-
Co coatings were deposited from an electrolyte bath con- ical tests, samples were covered by paraffin wax but leaving a
sisting of CoSO4 ·7H2 O (112 g L−1 ), H3 BO3 (40 g L−1 ) and Na2 SO4 1 cm2 surface area exposure to the corrosive medium for 30 min
(100 g L−1 ). For depositing GO/Co composite coating, GO (0.2 g L−1 ) to stabilize the system. The potentiodynamic polarization curves
was added in the electrolyte bath. The pH value of the bath was were recorded at a sweep rate of 0.5 mV s−1 from −200 to 200 mV
maintained at 5.0 adjusted by sulfuric acid and sodium hydroxide. versus the open circuit potential. As to electrochemical impedance
A copper plate was used as the working cathodes with dimensions spectroscopy (EIS) tests, the employed amplitude of the sinu-
of Ø25.0 × 2.0 mm. Prior to plating, the surface of the copper plate soidal signal was 10 mV, and the frequency range studied was from
was polished mechanically using abrasive paper (from 600 to 1500 105 to 10−2 Hz. ZView2 software was used for the data fitting of
grade) and sequentially cleaned with distilled water and acetone impedance spectra. The average value from three replicates for each
to remove contamination on the surface. The platinum mesh with kind of specimen was reported.
dimension of Ø 50.0 mm was used as the anode.
The Co and GO/Co composite coatings were fabricated using a
pulse electrodeposition at the temperature of 45.0 ◦ C for 2 h with 3. Results and discussion
help of magnetic stirring at the speed of 800 rpm. The pulse on-time
(ton ) and pulse off-time (toff ) were 0.3 ms and 0.7 ms, respectively. 3.1. Characterizations of GO
The average current density is 4.0 A dm−2 . The electrodeposi-
tion was conducted using an Intelligent Multiwave Electroplating Fig. 1 shows the TEM image, AFM image, cross-section graph,
Equipment supplied by Handan Dashun Electroplating Equipment XRD pattern and Raman spectra of GO sheets prepared in this exper-
Co. Ltd., China. iment. As shown in Fig. 1a, the GO nanosheets are highly thin with
few numbers of layers and very transparent with wrinkles on the
2.3. Characterizations of nanocrystalline Co and GO/Co coatings surface, which is similar to the GO morphology reported by Si et al.
[19]. The AFM image and the cross-section graph in Fig. 1b and c
The morphology of the GO was analyzed using a JEM-2010F shows that the thickness of GO nanosheets is about 1.0 nm. Fig. 1d
transmission electron microscope (TEM). The thickness of the GO shows that the carbon (0 0 1) characteristic peak of GO sheets at 10◦
was measured using a Bruker Multimode 8 atomic force microscopy is strong in the XRD pattern, which is same with the one reported
C. Liu et al. / Applied Surface Science 351 (2015) 889–896 891

Fig. 1. TEM image (a), AFM image (b), cross-section graph (c), XRD pattern (d), and Raman spectra (e) of GO nanosheets.

by Marcano et al. [20]. As shown in Fig. 1e, the Raman spectra show against the gray cobalt matrix. Fig. 3c confirms that the incorpo-
two prominent peaks at 1586−1 and 1327−1 , which correspond to rated GO sheets are highly dispersed in the composite coating.
the G band (E2g phonon of C sp2 atoms) and the D band (␬-point Fig. 4 shows the XRD patterns of the Co and GO/Co compos-
phonon of A1g symmetry) of GO, respectively [21]. ite coatings. The Co coating displays strong hcp (1 1 0) texture. In
contrast, the strong peak at (1 1 0) and a few new peaks at (1 0 0),
(0 0 2) and (1 0 1) are observed in the XRD pattern of the GO/Co
3.2. Morphology and microstructure of the coatings
composite coatings. In addition, the signs of peak broadening are
observed in the GO/Co composite coating, which might be result of
The SEM images of the surfaces and cross-sections of the Co and
the decreasing grain size in the composite coating.
GO/Co composite coatings are shown in Fig. 2. The electroplated Co
The average grain size calculated using the Scherrer’s equation
coating exhibits a smooth surface, as shown in Fig. 2a. The magni-
from XRD pattern and the microhardness of the Co and GO/Co com-
fied images (Fig. 2b and c) demonstrated that the Co coating has
posite coatings are shown in Table 1. The average grain size of the Co
a conical shaped structure. This conical shaped structure is a typ-
coating is around 50 nm but it is decreased to about 20 nm because
ical way of field oriented texture, i.e., the preferential growth in
of the incorporations of the GO nanosheets. The results show that
the direction of electric field [22]. Fig. 2d shows the cross-sectional
the produced Co and GO/Co composite coatings by pulse electrode-
view of the Co coating. It can be seen that the Co coating exhibits a
position are nanocrystalline structure. In addition, Table 1 shows
flat surface with thickness about 50 ␮m. The surface of the GO/Co
that the GO/Co composite coating has higher hardness than the
composite coating becomes rough and seems to be covered with the
pure Co coating. These results suggest that the incorporations of
co-deposited GO and Co grains (Fig. 2e). The amplified SEM image
GO into the Co matrix favor the formation of hcp (1 0 0), (0 0 2) and
(Fig. 2f) demonstrates that the GO/Co composite coating is featured
(1 0 1) textures and have functions of grain refining and hardness
with a mass of protruding structures, which might result from the
enhancement.
incorporations of GO nanosheets in Co matrix. Fig. 2g shows the
The electrocrystallization of Co is known to be an inhibited pro-
enlarged image of the zone marked with a black circle in Fig. 2f.
cess [23]. The different crystal orientations of the Co and GO/Co
Some wrinkled GO sheets are found on the surface of the compos-
composite coatings might be attributed to the changes in inhibiting
ite coating. The cross-sectional view (Fig. 2h) shows that the GO/Co
species. During the process of electrodeposition, both Co hydroxide
composite coating has an uneven surface with average thickness
and hydrogen are formed and partially absorbed onto the cathode
about 45 ␮m. And, a semicircle protruding structure is observed on
surface and may lead to the formation of (1 1 0) preferred orien-
the cross-sectional view, agreeing well with the SEM image shown
tation in Co deposits. As regards the GO/Co composite coating,
in Fig. 2e.
the additions of GO in the electrolyte can absorb Co2+ ions and
Fig. 3a shows the EDX spectrum from the image of Fig. 2g.
Co complexes. The absorbed cations are attracted to the growth
The elements of C and O in the EDX spectrum might derive from
center carrying with GO particles, which will shield the growing
the incorporated GO in the composite coating. The Raman spec-
troscopy and BS-SEM image of the GO/Co composite coating surface
are shown in Fig. 3b and c, respectively. As shown in Fig. 3b, the Table 1
composite coating exhibits two characteristic peaks of GO, corre- Average grain size and microhardness of the Co and GO/Co composite coatings.
sponding to the D band at 1322 cm−1 and G band at 1594 cm−1 ,
Sample Average grain size (nm) Microhardness (kgf mm−2 )
which suggests that GO sheets are successfully incorporated in
the composite coatings by pulse electrodeposition. In the BS-SEM Co 50 ± 5 340 ± 10
Co/GO 20 ± 2 430 ± 15
image (Fig. 3c), the lower atomic mass of carbon appears black
892 C. Liu et al. / Applied Surface Science 351 (2015) 889–896

Fig. 2. SEM images of the surfaces and the cross-sections of the Co and GO/Co composite coatings ((a) the Co coating surface; (b) and (c) magnified image of (a); (d)
cross-section of the Co coating; (e) the GO/Co surface; (f) magnified image of (e); (g) the enlarged image of the marked zone in (f); (h) cross-section of the GO/Co coating).
C. Liu et al. / Applied Surface Science 351 (2015) 889–896 893

Fig. 3. (a) EDX spectrum from the image of Fig. 2g; (b) Raman spectroscopy and (c) Backscattered (BS) SEM image of the GO/Co composite coating.

Fig. 4. XRD patterns of the Co coating (a) and the GO/Co composite coating (b).

centers from cations in electrolyte and prevent the further growth reaching 0.70 after sliding for 200 m. After that, it maintains at that
of Co grains. In this condition, re-nucleation occurs preferably on level till the end of the test. In contrast, the friction coefficient of
(1 0 0), (0 0 2) and (1 0 1) facets. However, the inhibitor species are the GO/Co composite coating increase rapidly and reach 0.25 after
not enough to affect the electrocrystallization of all grains. Thus, a short running distance less than 10 m and then experiences a long
the (1 1 0) preferred orientations still exist. In addition, there is and slight increase up till reaching 0.36 at the end of the test.
a competition between the nucleation and crystal growth during Fig. 6 shows the average friction coefficients and wear rates of
the growth of the electrodeposited layer [24], the GO nanosheets the Co and GO/Co composite coatings. The average friction coeffi-
absorbed on to the cathode surface hinder the crystal growth and cient of the GO/Co composite coating is 0.33 that is much smaller
increase nucleation sites for reduction of Co ions during deposition, than 0.65 for the pure Co coating. In addition, the wear rate of
which results in grain refining in the GO/Co composite coating [15]. the composite coating is lower than that of the pure Co coating.
The results confirm that the GO/Co composite coating has supe-
rior friction reduction and wear resistance than the Co coating.
3.3. Wear and corrosion resistance of the coatings
The significant decrease of the friction coefficient and wear rate
for the GO/Co composite coating can be explained as follow. First,
Typical friction coefficient curves of the Co and GO/Co composite
as one of the emerging self-lubricating materials, the uniformly
coatings are shown in Fig. 5. The friction coefficient of the Co coat-
ing increases steadily with the increase of the sliding distance till

Fig. 6. Average friction coefficients and wear rates of the Co and GO/Co composite
Fig. 5. Typical friction coefficient curves of the Co and GO/Co composite coatings. coatings.
894 C. Liu et al. / Applied Surface Science 351 (2015) 889–896

Fig. 7. SEM images of the wear scars for the Co and GO/Co composite coatings ((a–c) the Co coating; (d–f) the GO/Co composite coating).

distributed GO nanosheets in the composite coating lead to a sig- featured with severe plastic deformation, as shown in Fig. 7c. Fish-
nificant decrease of friction coefficient. Pan et al. [25] found that the scale like structure is observed on this wear surface. These results
incorporations of GO into monomer casting nylon largely reduced demonstrate that the severe adhesive wear has occurred during the
wear and friction under dry sliding. Kinoshita et al. [26] found that rubbing process for the pure Co coating. It is reasonable to conclude
adding GO monolayer in water improved lubricating properties that the severe adhesive wear results in the plastic deformation and
and provided a very low friction coefficient of approximately 0.05 accelerates the wear the pure Co coating. In contrast, the wear sur-
with no obvious surface wear after 60,000 cycles of friction test- face of the GO/Co composite coating is featured with slight plastic
ing. Second, the wear rate is inversely proportional to the hardness deformation, as shown in Fig. 7f. In addition, a few shallow scratches
of material according to the classical Archard’s law. As evidenced are also observed on this wear surface. It can be concluded that
before, the inclusions of GO enhance the hardness of the composite the composite coating has suffered from the abrasive wear and the
coating resulting in the improved wear resistance. slight adhesive wear.
SEM images of the wear scars on the Co and GO/Co composite The potentiodynamic polarization curves of the Co and GO/Co
coatings after rubbing are shown in Fig. 7. As shown in Fig. 7a, a clear composite coatings measured in 3.5 wt.% NaCl solutions are shown
and continuous wear scar is observed on the surface of the Co coat- in Fig. 8a. The corrosion potential (Ecorr ), corrosion current density
ing. On the contrary, the wear scar on the GO/Co composite coating (icorr ) and corrosion rate are calculated using the program CorShow
is discontinuous (Fig. 7d). The amplified SEM images of the wear from the potentiodynamic polarization curves. The calculated val-
scars in Fig. 7a and d are, respectively shown in Fig. 7b and e. When ues are listed in Table 2. As shown in Table 2, the Ecorr of the Co and
compared to the complete wear occurred on the surface of the Co the GO/Co coatings do not have much difference. The difference
coating (Fig. 7b), just a partial surface has experienced scuffing and around 40 mV is not enough to permit a clear distinction between
wear for the GO/Co composite coating (Fig. 7e). To interpret the the electrochemical behaviors of the samples examined [27]. How-
different wear mechanisms between the two coatings, the higher ever, the icorr of GO/Co composite coating is more than three times
magnifying SEM images of Fig. 7b and e are shown in Fig. 7c and f, decreases from Co coating. The GO/Co composite coating exhibits
respectively. The wear surface of the Co coating is very rough and low corrosion rate, approximately 31% that of Co coating. The result

Fig. 8. Potentiodynamic polarization curves (a), Nyquist plots (Inset: the equivalent circuit used to fit the EIS data) (b), and Bode plots (c) of the Co and GO/Co composite
coatings measured in 3.5 wt.% NaCl solution.
C. Liu et al. / Applied Surface Science 351 (2015) 889–896 895

Table 2 Acknowledgments
Corrosion potential (Ecorr ), corrosion current density (icorr ) and corrosion rate of the
Co and GO/Co composite coatings.
The authors are grateful to the support of the National Nat-
Sample Ecorr (mV) icorr (A·cm−2 ) Corrosion rate(mm y−1 ) ural Science Foundation of China (Grants: 51275176) and the
Co −
314.9 9.70 × 10−6 4.98 × 10−2 Fundamental Research Funds for the Central Universities (Grants:

GO/Co 359.7 3.04 × 10−6 1.56 × 10−2 2014ZG0014) for financial support.

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