Overview
Pulsed Electrodeposition is a unique non-line-of-sight electrolytic deposition technique for obtaining wear and corrosion resistant nanocrystalline coatings using modulated currents. The ions of metal of interest are reduced at the component surface under the influence of modulated current. The process utilizes non-hazardous electrolyte and pulsed current to achieve desired microstructure and mechanical properties in hardness gradient nanocrystalline Nickel, Sacrificial Zn, Nanocrystalline alloys of Ni-P, Ni-B, Ni-W, Ni-Mo, Fe-W, NiCoFe medium entropy alloys, Ni-W/SiC composite coatings.
The PED process offers significant advantages, including the higher rate of depositions, synthesis of bulk nanocrystalline coatings, alloys. Synthesis of hardness gradient and multilayered coatings as well as composites. The setup accommodates components up to 500 cm2 in the form of rods, cylinders, complex geometry for developing wear and corrosion resistant coatings for application in sectors such as automotive, aerospace, manufacturing, defence, electronics, and heavy engineering.
Key Features
- Non line of site process, economical and ecofriendly
- Porosity free finished product, higher production rates
- Control over microstructure, mechanical properties, particle content in composite coating
- Higher current efficiency and deposition rates compared to traditional hard chrome process
- Easy technology transfer from research lab to existing infrastructure
Potential Applications
- Hard chrome replacement – hardness up to 7-12 GPa:
- Ni-W
- Ni-W/SiC nanocomposite
- Wear-resistant coatings for actuators, dies – friction coefficient < 0.5
- Corrosion coatings for actuators – thickness up to 100 μm
- Decorative coatings for aesthetic applications
Status
- Performance and stability are validated at laboratory and industry scale
- Scale-up version is also available up to 500 cm2 for industrial component
Intellectual Property Development Index (IPDI)
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Description
Basic concepts and understanding of underlying scientific principles
Shortlisting possible applications
Research to prove technical feasibility for targeted application
Coupon level testing in simulated conditions
Check repeatability/consistency
Prototype testing in real-life conditions
Check repeatability/consistency
Reassessing feasibility (IP, competition technology, commercial)
Initiate technology transfer
Support in stabilizing production
Status
| Level | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
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| Description | Basic concepts and understanding of underlying scientific principles | Shortlisting possible applications | Research to prove technical feasibility for targeted application | Coupon level testing in simulated conditions | Check repeatability/consistency | Prototype testing in real-life conditions | Check repeatability/consistency | Reassessing feasibility (IP, competition technology, commercial) | Initiate technology transfer | Support in stabilizing production |
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US Patent # 11732375 B2 (Granted on 22/08/2023): Iron tungsten coating formulations and processes.
Indian Patent # 285178 (Granted on 14/07/2017): An improved method for preparing nickel electrodeposit having predetermined hardness gradient.
Indian Patent # 337108 (Granted on 20/05/2020): A method and an apparatus for preparing nickel tungsten-based nanocomposite coating deposition.
- Influence of Sliding Velocity on Wear Behavior of Electrodeposited Ni-W and Hard Chrome Coatings on Gun Barrel Steel. J. of Materi Eng and Perform (2025).
- Achieving Exceptional Strain-Hardening Ability in Nanocrystalline Ni-W Coatings through Compositionally Modulated Multilayer Approach, Materials Science and Engineering A 912 (2024) 146971.
- Influence of compositional and microstructural gradient on the wear performance of nanocsrystalline Ni-W coatings, Wear 530-531 (2023) 205039.