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Ni-Co composite coatings reinforced with ZrO2 were obtained by ultrasound-assisted electrodeposition. The electrodeposition kinetics were investigated using linear sweep and cyclic voltammetry. The morphology and coating phases of the coatings were characterized by scanning electron microscopy and X-ray diffraction, respectively. Results indicated that the electrocrystallization of Co was controlled by a three-dimensional “nucleation/growth” process. The initial co-deposition potentials of the alloy and composite coatings were −0.72 V vs. SCE and −0.70 V vs. SCE, respectively. During co-deposition, ZrO2 restrained the discharge of H + and reduced the cathodic polarization. When the amount of added ZrO2 was 10 g L− , the nanohardness, anti-corrosion and wear resistance of the Ni-Co/ZrO2 composite were evidently improved compared with the Ni-Co alloy. The average nanohardness of the Ni-Co/ZrO2 composite was 6.13 GPa, which was approximately 1.5 times higher than that of the Ni-Co alloy (4.12 GPa). After 40 min of rotational wear testing, the wear loss of the Ni-Co alloy was approximately twice compare with the Ni-Co/ZrO2 composite. The high hardness and low defect density in the composite coatings reduced the plastic deformation and adhesive wear of the Cu substrates, leading to a significant improvement wear properties.

Electrochemical and Tribological Behavior of Ni-Co/ZrO2 Coatings Prepared by Ultrasound-Assisted Electrodeposition