The Effect of Current Density and Cathode Position on the Corrosion Resistance and Thermal Emission Properties of Nickel Electroplated Layers on Brass Surfaces

Brass components are widely used in heat dissipation and thermal emission devices due to their high thermal conductivity and ease of processing. However, these applications demand good thermal oxidation resistance, high emissivity, and excellent corrosion resistance. In this study, nickel coatings were deposited on brass substrates by direct current electroplating, and the effects of current density and cathode configuration on the microstructure, emissivity, and corrosion resistance of the coatings were systematically investigated. The results show that the emissivity of the coatings first increased and then decreased with increasing current density. Optimal performance was achieved when the cathode and anode were positioned perpendicular to the horizontal plane at a current density of 3.0 A·dm−2. Under these conditions, the coatings exhibited a smooth, uniform, and dense microstructure, with evenly distributed metallic grains. Electrochemical polarization and impedance measurements further confirmed the superior corrosion resistance of this coating, with a minimum corrosion current density of 0.259 μA·cm−2, a maximum polarization resistance of 6381.55 Ω·cm2, and a minimum corrosion rate of 0.023 mm/a. These findings demonstrate a simple and effective approach to enhancing both the emissivity and corrosion resistance of brass substrates, offering practical value for thermal management applications.