Electroless Ni-P-ZrO 2 composite coatings on AZ91D magnesium alloys was developed and their characteristics were investigated. The experimental results showed that the composite coatings were uniform and compact. The hardness of Ni-P-ZrO 2 composite coatings reached the maximum value at 350uC heat treatment, and then decreased at 400uC. The nickel phosphor alloys provided solution strengthening and precipitation strengthening, while the ZrO 2 nanoparticles provided dispersion hardening, making the composite coatings harder than that of Ni-P coatings. The wear resistance of Ni-P-ZrO 2 composite coatings was obviously superior to Ni-P coatings, especially with longer wear time, which can be attributed to the dispersion strengthening and load support effect of ZrO 2 in the coatings. The Ni-P-ZrO 2 coatings exhibited better corrosion resistance than that of Ni-P coatings owing to codeposition of ZrO 2 together with NiP leading to a more compact composite coating.
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