Influence of DLC-Cu particles on structure and properties of Ni composite coating deposited via direct-current electrodeposition

Incorporation of solid lubricants into electrodeposited Ni composite coatings is an effective strategy for improving tribological performance; however, conventional reinforcements such as graphite, graphene oxide (GO), and carbon nanotubes (CNT) often suffer from weak interfacial bonding and particle agglomeration, which limit hardness improvement. Metallic particles such as Cu enhance interfacial compatibility with the Ni matrix but provide insufficient lubrication. To overcome these limitations, this study investigates the role of core-shell diamond-like carbon-coated Cu (DLC-Cu) particles as dual-function reinforcement in Ni composite coatings fabricated via direct current electrodeposition. The influence of Cu and DLC-Cu particles on coating growth behavior, microstructure evolution, hardness, and tribological performance was systematically evaluated. Surface morphology and structural characteristics were analyzed using SEM, EDS, 3D optical profilometry, and XRD, while co-deposition behavior was examined through visual observation and zeta potential measurements. Tribological performance was assessed using a ball-on-disk tribometer, Raman spectroscopy and XPS analysis confirmed the formation of a lubricating tribolayer. The results showed that conductive Cu particles increased the number of Ni nucleation sites and promoted coating thickening, resulting in protruding nodular structures, whereas DLC–Cu particles produced a more uniform coating due to improved particle dispersion during Ni growth. The Ni composite coating reinforced with 1 g/L DLC-Cu exhibited the highest hardness (5.45 ± 0.54 GPa), lowest friction coefficient (0.54), and approximately 86.8% reduction in wear rate compared with the Ni-Cu composite coating. These findings demonstrate that DLC-Cu core-shell particles provide synergistic strengthening and lubrication effects, enabling the development of self-lubricating Ni composite coatings for advanced tribological applications.

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