Gradient-structured ternary Fe-Co-Ni alloy coatings electrodeposited on steel substrates at various current densities from chloride baths were numerically and experimentally investigated. The electrodeposition process, considering hydrogen evolution and hydrolysis reaction, was modelled using the finite element method (FEM) and was based on the tertiary current distribution. The experimentally tested coating thickness and elemental contents were used to verify the simulation model. Although there was a deviation between the simulation and experiments, the numerical model was still able to predict the variation trend of the coating thickness and elemental contents. The influence of the current density on the coating characterization was experimentally studied. Due to hydrogen evolution, the coating surface exhibited microcracks. The crack density on the coating surface appeared smaller with increasing applied current density. The XRD patterns showed that the deposited coatings consisted of solid-solution phases α-Fe and γ (Fe, Ni) and the metallic compound Co₃Fe₇; the current density in the present studied range had a small influence on the phase composition. The grain sizes on the coating surface varied from 15 nm to 20 nm. The microhardness of the deposited coatings ranged from 625 HV to 655 HV. Meanwhile, the average microhardness increased slightly as the current density increased from 5 A/dm² to 10 A/dm² and then decreased as the current density further increased. Finally, the degree of anomaly along with the metal ion and hydrogen atom concentrations in the vicinity of the cathodic surface were calculated to investigate the anomalous codeposition behaviour.

1. Electrodeposition is a convenient and cost-effective method for the fabrication of functional, protective, and decorative coatings. Good anti-corrosion properties, high hardness, and bright appe...

Fe-based amorphous composite coatings are promising surface coating materials, because of their low cost, high hardness, and superior wear resistance. In the present study, Fe-based composite coatings with various amorphous contents (35.9–59.3%) were deposited onto 1045 steel via laser cladding, and the influence of laser-cladding parameters on the amorphous content was analysed. The cross sections of the coating layer and ground coating surface were then characterised in terms of the microstructure, phase composition, amorphous content, grain size, and microhardness. Importantly, the tribological properties of coatings with various amorphous contents under both dry and lubricated sliding conditions with light and heavy loads were systematically investigated. The microstructure of the crystalline/amorphous mixture was found to be a function of the temperature gradient, cooling rate, and chemical composition. The high microhardness was related to the amorphous content and grain size. The tribological properties were found to be insensitive to the amorphous content under both dry and lubricated conditions under light and heavy loads. The manifold morphologies of the wear tracks and the transition of the wear mechanism were the result of the combined effects of the amorphous content, phase composition, and size and distribution of the crystalline phase.