Designing nickel coatings for water erosion performance: Optimisation of grain size and thickness

Metallic coatings are gaining interest as an alternative to classical polymeric layers for erosion damage prevention due to their extended durability and sustainability. However, their implementation requires a thorough understanding of protective potential and reliability. This study explores the use of brush-plated nickel coatings on carbon-fibre reinforced composites to enhance their performance against water erosion. A combination of experimental analysis and computational modelling explores the effect of different coating thickness and properties to withstand water droplet erosion damage. Findings reveal a minimum critical coating thickness around 40 μ m can significantly improve the erosion resistance. • Metallic coatings offer a durable, sustainable alternative for erosion protection. • Nickel-coated CFRPs need ≥ 40 μ m thickness to improve erosion resistance. • Combined testing and modelling linked erosion to coating thickness & microstructure. • Research informs parameter control to enhance coating life in erosive conditions.