High-phosphorus Ni–P-WS2 composite coatings prepared by electroless plating: corrosion resistance and wear resistance

A high-phosphorus Ni–P composite coating co-deposited with tungsten disulfide (WS₂) particles was prepared by electroless plating to improve the wear and corrosion resistance of metal components. The influence of WS₂ concentration (0–4 g/L) on the microstructure, corrosion behavior, and tribological properties was systematically studied. Electrochemical tests showed that the coating with 2 g/L WS₂ exhibited the best corrosion resistance, as evidenced by its noblest corrosion potential (–0.548 V), highest charge transfer resistance in electrochemical impedance spectroscopy, and lower corrosion current density (7.035 × 10⁻⁶ A/cm 2 ). The long-term corrosion resistance of this optimal coating was further validated through a 7-day neutral salt spray test. In addition, the composite coating demonstrated excellent wear resistance with an ultra-low average friction coefficient of 0.024 and a wear rate of 2.7 × 10⁻ 5 mm 3 ·N⁻ 1 ·m⁻ 1 . This study successfully developed a Ni–P-WS₂ composite coating with balanced improvements in both long-term corrosion protection and wear resistance, showing great potential for industrial applications.