Enhanced mechanical and electrochemical behavior of electrodeposited Ni-B-NbC coatings: experimental characterization and COMSOL simulation

TY – JOUR

T1 – Enhanced mechanical and electrochemical behavior of electrodeposited Ni-B-NbC coatings

T2 – experimental characterization and COMSOL simulation

AU – Samra, Ahmad Saadi

AU – Zafar, Samra

AU – Ahmad, Muhammad

AU – Husnain, Muhammad

AU – Kahraman, Ramazan

AU – Mansoor, Bilal

AU – Ali, Kamran

AU – Shakoor, R. A.

N1 – Publisher Copyright:
© 2026

PY – 2026/5

Y1 – 2026/5

N2 – This study investigates the fabrication of Ni-B-NbC composite coatings using the electrodeposition technique, where different loadings of Niobium Carbide (NbC) particles were introduced into a Nickel‑boron matrix (Ni-B). The effect of NbC incorporation with different concentrations (2, 4, and 6 g/L) on the coating’s structural morphology, surface characteristics, mechanical strength, and electrochemical behavior was comprehensively analyzed. Structural observations confirmed that NbC particles were successfully embedded within the Ni-B matrix, while maintaining the characteristic cauliflower-like surface texture. The microhardness of the coatings increased progressively with higher NbC content, achieving a peak value of 1873 HV at 6 g/L. Similarly, the corrosion resistance enhanced consistently, with the maximum charge transfer resistance (Rct) reaching 5260 Ω·cm2 at the same particle concentration. The optimized Ni-B-NbC coating (6 g/L) exhibited simultaneous improvements in hardness (∼127%) and corrosion resistance (∼92%) compared with the unreinforced Ni-B layer. These enhancements stem from dispersion strengthening and refinement of the grain structure, which collectively harden the matrix and reduce active surface exposure. Additionally, the filling of micro-defects by NbC particles contributes to the barrier effect. Complementary COMSOL Multiphysics simulations revealed that the co-deposition of NbC modifies the local current density distribution during electrodeposition, influencing coating uniformity and integrity. The overall improvement in corrosion and mechanical aspects indicates the potential of Ni–B–NbC composite coatings for harsh service environments in oil and gas, automobile, and aerospace applications.

AB – This study investigates the fabrication of Ni-B-NbC composite coatings using the electrodeposition technique, where different loadings of Niobium Carbide (NbC) particles were introduced into a Nickel‑boron matrix (Ni-B). The effect of NbC incorporation with different concentrations (2, 4, and 6 g/L) on the coating’s structural morphology, surface characteristics, mechanical strength, and electrochemical behavior was comprehensively analyzed. Structural observations confirmed that NbC particles were successfully embedded within the Ni-B matrix, while maintaining the characteristic cauliflower-like surface texture. The microhardness of the coatings increased progressively with higher NbC content, achieving a peak value of 1873 HV at 6 g/L. Similarly, the corrosion resistance enhanced consistently, with the maximum charge transfer resistance (Rct) reaching 5260 Ω·cm2 at the same particle concentration. The optimized Ni-B-NbC coating (6 g/L) exhibited simultaneous improvements in hardness (∼127%) and corrosion resistance (∼92%) compared with the unreinforced Ni-B layer. These enhancements stem from dispersion strengthening and refinement of the grain structure, which collectively harden the matrix and reduce active surface exposure. Additionally, the filling of micro-defects by NbC particles contributes to the barrier effect. Complementary COMSOL Multiphysics simulations revealed that the co-deposition of NbC modifies the local current density distribution during electrodeposition, influencing coating uniformity and integrity. The overall improvement in corrosion and mechanical aspects indicates the potential of Ni–B–NbC composite coatings for harsh service environments in oil and gas, automobile, and aerospace applications.

KW – Corrosion

KW – EIS

KW – Electrodeposition

KW – Microhardness

KW – Ni-B-NbC

UR – www.scopus.com/pages/publications/105028922097

U2 – 10.1016/j.mseb.2026.119222

DO – 10.1016/j.mseb.2026.119222

M3 – Article

AN – SCOPUS:105028922097

SN – 0921-5107

VL – 327

JO – Materials Science and Engineering: B

JF – Materials Science and Engineering: B

M1 – 119222

ER –