Thermal–Alkaline Etching of SiC Nanoparticles for Colloidal Stabilization and Enhanced Wear Resistance in Electrodeposited Co/SiC Coatings

Composite electrodeposited coatings hold significant potential for marine and aerospace applications due to their synergistic corrosion resistance and wear durability, yet nanoparticle agglomeration and interfacial incompatibility persistently undermine their performance. Conventional dispersion techniques—mechanical agitation, surfactants, or high-energy methods—fail to resolve these issues, often introducing residual stresses, organic impurities, or thermal damage to substrates. This study addresses these challenges through a novel thermal-assisted alkaline etching (TAE) protocol that synergistically removes surface oxides and enhances colloidal stability in β-SiC nanoparticles. By combining NaOH-based etching with low-temperature calcination (250 °C), the method achieves oxide-free SiC surfaces with elevated hydrophilicity and a ζ-potential of −25 mV, enabling submicron clustering (300 nm) without surfactants. Electrodeposited Co/SiC coatings incorporating TAE-SiC exhibited current-modulated reinforcement, achieving optimal SiC incorporation (5.9 at% Si) at 8 A/dm2 through electrophoretic–hydraulic synergy, along with uniform cross-sectional distribution validated by SEM. Tribological assessments revealed shorter wear tracks in TAE-SiC-enhanced coatings compared to their untreated counterparts, suggesting enhanced interfacial coherence despite a comparable mass loss. Demonstrating scalability through cost-effective aqueous-phase chemistry, this methodology provides a generalized framework applicable to other ceramic-reinforced systems (e.g., Al2O3 and TiC), offering transformative potential for next-generation protective coatings in harsh operational environments.