Optimization of the Properties of Electrodeposited Ni-YSZ Composites Using Taguchi Method and Regression Analysis

Properties of electrodeposited Ni-composite coatings containing ceramic particles are very much dependant on the bath used, current density, duration of deposition, particle content in the bath, etc. In the present study, the influence of process parameters like the concentration of particles, current density and time of deposition on the area fraction of yttria stabilized zirconia (YSZ), the microhardness and the thickness of the electrodeposited nickel (Ni)-YSZ composite coating was analyzed by Taguchi Design method and analysis of variance (ANOVA). According to the experimental results and ANOVA, the interaction of current and time are the most significant factors influencing the thickness of the coating; interaction of concentration of particles in the electrolyte bath and current are the most significant factors influencing the microhardness; and concentration of particles in the electrolyte bath is the most significant factor affecting the area fraction of particles in the Ni matrix. Models were developed for predicting the microhardness and thickness of the composite coating and area fraction of particles incorporated in the nickel matrix. They were found to be in good agreement with the experimental results. The models were tested for experimental conditions and were found to be close to predicted values. The thickness of the deposit was mainly dependent on the current density and duration of plating. On the other hand, the microhardness of the coating and area fraction of particles present in the nickel matrix were mainly dependent on the amount of particles present in the bath.