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Surface Defect Mitigation of Additively Manufactured Parts Using Surfactant-Mediated Electroless Nickel Coatings
Anju Jolly1,2, Véronique Vitry2, Golnaz Taghavi Pourian Azar1
1The Functional Materials and Chemistry Group, Centre for Manufacturing and Materials, The Institute for Advanced Manufacturing and Engineering, Coventry University, Beresford Ave., Coventry CV6 5LZ, UK.
Materials (Basel, Switzerland)
|January 23, 2024
Summary
Electroless nickel-boron deposition effectively fills defects in additively manufactured ferrous alloys. Surfactants like polyethylene glycol significantly improve defect filling and surface leveling for enhanced part quality.
Area of Science:
- Materials Science
- Surface Engineering
- Additive Manufacturing
Background:
- Defects like lack of fusion and gas entrapment in additively manufactured (AM) ferrous alloys compromise mechanical performance.
- These defects manifest as surface roughness and porosities, limiting AM part applications in aerospace and medicine.
Purpose of the Study:
- To evaluate electroless nickel-boron (Ni-B) deposition as a method for filling and leveling simulated AM defects.
- To investigate the role of surfactants in controlling surface roughness and promoting defect filling.
Main Methods:
- Simulated AM defects were targeted using an electroless Ni-B deposition process.
- Cationic (CTAB) and nonpolar (PEG) surfactants were tested at various concentrations in a Ni-B electrolyte.
- Surface roughness and defect filling were analyzed based on surfactant type and concentration.
Main Results:
- Electroless Ni-B deposition efficacy was significantly influenced by surfactant concentration and type.
- Heavy-molecular-weight polyethylene glycol (PEG) at 1.2 g/L yielded the highest defect leveling percentages.
- Surfactants helped attenuate surface roughness, promoting preferential defect filling.
Conclusions:
- Electroless Ni-B deposition presents a promising approach for repairing defects in ferrous-based AM parts.
- Optimized surfactant use in Ni-B plating can enhance surface quality and mechanical integrity of AM components.
