This study introduces a novel Ni/NiCr/NiCrAlSi composite coating to enhance the corrosion resistance of copper, particularly for its use in marine heat exchangers. Utilizing characterization techniques such as scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS), the paper investigates the coating’s composition, structure, and corrosion resistance in 3.5 wt.% NaCl aqueous solutions. A significant focus is placed on the role of aluminum within the NiCrAlSi layer, examining its influence on the coating’s structure and corrosion behavior. The results indicate that the NiCrAlSi layer with an aluminum content of 5.49 at.% exhibits the most improved corrosion resistance, characterized by the highest corrosion potential and a corrosion current density that is more than one order of magnitude lower compared to the Ni/NiCr coating. The effectiveness of this composite coating is attributed to its multilayer structure and the synergistic effect of alloying elements Cr, Al, and Si, which collectively inhibit corrosive medium penetration. These insights present the Ni/NiCr/NiCrAlSi coating as a promising candidate for copper protection in sea water environments, merging enhanced durability with cost-effectiveness.

Here, 2% Cu + 2% Ni co-doped ZnO nanoparticles were synthesized using the hydrothermal method and were used as particle reinforcements of Cu-Ni nanocomposite coatings prepared by electroplating technology. The effects of the added (Cu, Ni) co-doped ZnO nanoparticles (2–8 g/L) on the phase structure, surface morphology, thickness, microhardness, corrosion resistance, and photocatalytic properties of the coatings were investigated. The nanocomposite coatings have obvious diffraction peaks on the crystal planes of (111), (200), and (220), showing a wurtzite structure. The surface of the nanocomposite coatings is cauliflower-like, and becomes smoother and denser with the increase in the addition of nanoparticles. The grain size, thickness, microhardness, corrosion resistance, and photocatalytic properties of the nanocomposite coating reach a peak value when the added (Cu, Ni) co-doped ZnO nanoparticles are 6 g/L. At this concentration, the mean crystallite size of the coating reaches a minimum of 15.31 nm, and the deposition efficiency of the coating is the highest. The (Cu, Ni) co-doped ZnO nanoparticle reinforcement makes the microhardness reach up to 658 HV. The addition of nanoparticles significantly improves the corrosion resistance and photocatalytic properties of nanocomposite coatings. The minimum corrosion current density is 2.36 × 10⁻⁶ A/cm², the maximum corrosion potential is −0.301 V, and the highest decolorization rate of Rhodamine B is 28.73% after UV irradiation for 5 h.