Electrodeposition of Amorphous Cobalt–Phosphorus Coating

Amorphous cobalt-phosphorous (CoP) coatings are a candidate to replace hard chromium and other traditional coatings. Here, electrodeposition of both amorphous and crystalline CoP coatings was performed at room temperature and in an air environment. The bath composition and deposition conditions were optimized to offer a low cost, low maintenance, and safe process. The effects of various deposition variables such as solution composition, pH, duration, and mixing parameters were studied, and the reproducibility of the process was demonstrated. Selected coatings were then thoroughly characterized by a variety of techniques. The best amorphous/nanocrystalline coating contained ca. 6.4 wt.% P after 1.2 h of deposition, and 7.2 wt.% P after 4 h of deposition. The best crystalline coating contained ca. 2.7 wt.% P after 1.2 h of deposition and between 2.3 and 5.5 wt.% P after 4 h of deposition. The amorphous coating had excellent mechanical properties: a high hardness (7.8 ± 0.7 GPa), high Young's modulus (153 ± 9 GPa), and surprisingly low coefficient of dry friction (between 0.11 ± 0.02 and 0.17 ± 0.01). The coating could not be scraped from the substrate using a diamond scalpel blade. In a standard adhesion test, the sample failed neither cohesively within the coating nor adhesively between the coating and the substrate. In the as-deposited conditions, the structure was uniform, nanocrystalline, or had nanocrystals embedded in an amorphous matrix. The crystallization temperature of the amorphous alloy was 284 °C, and the phase transformation occurred only between 300 and 400 °C. The coatings developed and comprehensively characterized herein may be considered for aerospace, magnetic storage, fuel cells, water splitting, and other applications.