Optimization of Plating Parameters and Properties of Ultrasonic-Assisted Jet-Electrodeposited Ni-W-Al2O3 Nanocomposite Coatings

Ni-W-Al₂O₃ nanocomposite coatings were fabricated using ultrasonic-assisted jet electrodeposition (UAJED) to improve the wear resistance of agricultural machinery parts. To find the best combination of process parameters, the response surface plotter, contour plotter, and pre-set plotter in the JMP (version Pro 14.3.0) software were employed to investigate the effects of various process parameters (jet rate, Al₂O₃ content, and ultrasonic power) on the microhardness of the nanocomposite coatings. The surface morphology, microstructure, and properties of the coatings, which were prepared under various combinations of process parameters, were studied through scanning electron microscopy (SEM), an X-ray diffractometer (XRD), transmission electron microscopy (TEM), a microhardness tester, and tribemates to determine the optimal process parameters for creating Ni-W-Al₂O₃ nanocomposite coatings. The results indicated that the jet rate, Al₂O₃ content, ultrasonic power, interaction terms, and quadratic terms significantly influenced the microhardness of the coatings. The optimized process parameters using the JMP software were a jet rate of 3.71 m/s, Al₂O₃ content of 15.38 g/L, and ultrasonic power of 210 W. Furthermore, the coatings produced under these optimal conditions showed low wear rates and friction coefficients, a refined grain size, a dense surface topology, and a high microhardness (724.9 HV).