Enhanced Mechanical and Corrosion Performance of NiP Coatings via Pulse Electrodeposition with Optimized WS ₂ Nanoplatelet Reinforcement

This study investigates the structural, tribological, and electrochemical properties of nickel–phosphorus–tungsten disulfide (Ni–P–WS 2 ) composite coatings fabricated by pulse electrodeposition with different WS 2 concentrations. The incorporation of WS 2 nanoplatelets significantly influences the coating morphology, grain size, hardness, wear rate, and corrosion resistance. Microstructural analysis reveals grain refinement and formation of dense, defect‐free coatings at optimal WS 2 content. The sample containing 8 g L −1 WS 2 exhibits superior performance, achieving a peak microhardness of 640 HV and the lowest wear rate of 1.18 × 10 −6 mm 3 N −1 m −1 . Electrochemical measurements indicate a notable enhancement in corrosion resistance at this concentration, with reduced corrosion current density and elevated charge transfer resistance. However, excess WS 2 (>8 g L −1 ) leads to particle agglomeration, which negatively affects coating uniformity and performance. These results highlight the critical role of WS 2 dispersion and concentration in enhancing the multifunctional properties of NiP coatings, making them suitable for high‐performance applications in marine, chemical, and aerospace industries.