3.1. Deposition of cobalt layer on copper by galvanic replacement
As shown in Fig. 1a, the actual potential of cobalt sheet in 0.4 mol/L CoCl2 solution was − 0.427 V, which was lower than that of copper sheet (− 0.163 V), complying with the metal activity series. Therefore, it was impossible to deposit a cobalt layer on copper by galvanic replacement in CoCl2 solution. However, the actual potential of copper sheet significantly decreased to − 0.610 V in 8 mol/L NaI solution, while the actual potential of cobalt sheet slightly increased to − 0.195 V. The actual potential of cobalt sheet was higher than that of copper sheet in high concentration NaI solution. That was mainly because of the strong copper complexation and weak cobalt complexation ability of I−. In addition, the actual potential of cobalt sheet (− 0.173 V) was still higher than that of copper sheet (− 0.577 V) in 8 mol/L NaI solution containing 0.4 mol/L CoCl2, indicating that copper was likely to react with cobalt ions in this solution. The special complexation ability of I− made the deposition of cobalt layer on copper by galvanic replacement possible.
The effect of cobalt ion concentration in NaI solution on depositing cobalt layers on the copper substrate by galvanic replacement was explored. The morphological, compositional and structural characterization results shown in Fig. 2 indicated that the cobalt ion concentration had a significant effect on the galvanic replacement reaction rate between copper substrate and cobalt ions in NaI solution. When the concentration of cobalt ion was 0.05 mol/L, a cobalt layer could be obtained on copper, but there were several cracks and pores, which was the typical phenomenon of galvanic replacement deposition. The cobalt layer was mainly composed of nanoparticles with a size of less than 100 nm, suggesting the fast nucleation process of galvanic replacement reaction. The cobalt content in the sample was 7.23 at.%, indicating that only little cobalt could be deposited on the copper surface. When the concentration of cobalt ion increased to 0.1 mol/L and 0.2 mol/L, the cobalt content in the sample increased to 11.43 at.% and 12.28 at.%, and relatively complete cobalt layers could be obtained. However, there were still a few pores in the cobalt layers. When the concentration of cobalt ions continued to raise to 0.4 mol/L and 0.8 mol/L, complete cobalt layers could be obtained on copper and the cobalt content was increased to 17.06 at.% and 19.72 at.%, respectively. The galvanic replacement deposition rate of cobalt layer was increased with the increase of CoCl2 concentration in the NaI solution. It could also be found that there was some content of iodine element (less than 1 at.%) in all samples, which was generated owing to the high concentration of iodide in the deposition solution.
The diffraction pattern for the cobalt layer obtained from the solution containing 0.4 mol/L Co2+ was shown in Fig. 2f. It can be found that there were obvious diffraction peaks of the copper substrate at 43.5°, 50.4°, 74.0°, 89.9° and 95.6° because of the limited thickness of cobalt layer. In addition, the diffraction peak of the cobalt layer at 44.4° was overlayed with the diffraction peak of copper substrate at 43.5°. The diffraction peaks of the cobalt layer at 51.6° was overlayed with the diffraction peak of the copper substrate at 50.4°.
The XPS survey showed the existence of Co, Cu, and I elements in the cobalt layer, which was in good agreement with the EDS analysis results. Figure 3a and 3b presented the high-resolution 2p spectra in the Co (2p) and I (2p) regions for the as-prepared Co layer from the solution containing 0.4 mol/L Co2+. The peaks appearing at 780.5 eV and 796.6 eV in Fig. 3a were attributed to Co2p3/2 and Co2p1/2, respectively, which corresponded well to metallic Co, confirming the replacement deposition of cobalt on copper. The satellite peaks at 786.2 eV and 804.5 eV and the corresponding oscillation peaks could be attributed to divalent cobalt owing to the oxidation of cobalt. The distinct I3d5/2 and I3d3/2 peaks at 619.0 eV and 630.7 eV presented in Fig. 3b indicated that partial iodide was generated in the cobalt layers during the replacement deposition of cobalt on copper.
Figure 4a and 4d show the cross-sectional morphology of the cobalt layer. It can be found that a thin cobalt layer with a thickness of about 200 nm had been deposited on the copper substrate, as verified by the element distribution map shown in Fig. 4b and 4c. An obvious interface and some pore defects could be found between the cobalt layer and copper substrate. The pore defects were generated owing to the result of obvious corrosion of the copper substrate caused by the galvanic replacement reaction between the copper substrate and cobalt ions. The cobalt layer was deposited on copper according to the following reactions:
Anodic reaction: Cu + 2I− → [CuI2]− + e− (1)
Cathodic reaction: Co2+ + 2e− → Co (2)
Copper was eroded in the high concentration I− solution and [CuI2]− was generated because of the strong complexing ability of iodide to copper. Meanwhile, the cobalt ions could be reduced to cobalt and form a compact cobalt layer on copper substrate. This reaction process could be roughly illustrated by Fig. 5.
In order to verify the activation ability of deposited cobalt lay to electroless Ni-P plating, the cobalt layers on copper obtained from 8 mol/L NaI solutions with different Co2+ concentrations were immersed in the acidic and alkaline electroless Ni-P plating baths, respectively. Figure 6a shows the weight gain of Ni-P coatings obtained on cobalt layer from acidic or alkaline electroless Ni-P plating bath at 90°C for 30 min. It can be seen that there was no Ni-P coating on the cobalt layer obtained from 0.05 mol/L and 0.1 mol/L CoCl2 owing to the limited cobalt deposition. When the CoCl2 concentration increased to 0.2 mol/L, obvious Ni-P could be obtained from both acidic and alkaline electroless plating bath. The weight gain of Ni-P coating (26 mg) in alkaline electroless plating bath was higher than that (14 mg) in acidic electroless plating bath. With the increasing of CoCl2 concentration in the deposition solution, the weight gain of Ni-P coatings from alkaline electroless plating bath was firstly increased to 36 mg and then decreased to 30 mg. However, the weight gain of Ni-P coating from acidic electroless plating bath was relatively stable. The above results suggested that the sufficient cobalt layer had enough activation ability to initiate electroless Ni-P plating.
The morphology, composition and performance of Ni-P coating on cobalt layer obtained from solution containing 0.4 mol/L was characterized and compared with the Ni-P coating on the traditional palladium layer.
3.2 Morphology, composition of Ni-P coatings on cobalt and palladium layers
As shown in Fig. 7, the acidic Ni-P coating obtained on both cobalt and palladium layers was homogeneous and dense, and the EDS results indicated that the phosphorus content in the Ni-P coatings were 19.80 at.% and 18.80 at.%, respectively. The phosphorus content in the Ni-P coating by cobalt layer activation was a little higher than that of the Ni-P coating by palladium layer activation. The crystal structures of the acidic Ni-P coatings prepared on the surfaces of the nickel and palladium layers were characterized by XRD, and it was observed that the acidic Ni-P coating on the surface of the cobalt and palladium layers had similar structures and both were semi-amorphous. There was a main broad peak with 2θ angular range of about 37–55° which corresponds to the nickel plane.
The detailed composition of the acidic Ni-P coatings on cobalt and palladium layers obtained from acidic electroless plating solution were analyzed by XPS, and the high-resolution spectra of Ni and P elements were shown in Fig. 8. It can be found that both Ni-P coatings showed similar nickel and phosphorus spectra, indicating comparable activation ability of cobalt and palladium.
As shown in the Ni 2p spectra (Fig. 8a and Fig. 8c), most of the cobalt corresponded to nickel metal with binding energies of 851.8 eV and 868.9 eV. Also, there were two other major peaks at 855.5 eV and 873.3 eV and their nearby satellite peaks at binding energies of 858.5 eV and 875.9 eV. This indicated the presence of other nickel-containing compounds due to the oxidation and phosphorylation of nickel [26]. The spectra of phosphorus (Fig. 8b and Fig. 8d) expressed that the peaks at 128.6 eV and 129.4 eV corresponded to P2p3/2 and P2p1/2 of phosphorus in the Ni-P plating [27]. In addition, the peak positioned at 132.0 eV could be recognized as the hypophosphites or phosphorus in its intermediate chemical states as the solid solution in Ni-P coatings. The binding energy of the two peaks of phosphorus in the Ni-P coating activated by the cobalt layer was lower than that of the phosphorus peak in the Ni-P coating activated by the palladium layer, which might be due to the fact that the phosphorus content in the Ni-P coating activated by the cobalt layer was higher than that in the Ni-P coating activated by the palladium layer.
As shown in Fig. 9, the surface morphology of the Ni-P coatings on cobalt and palladium layers obtained from alkaline electroless plating solution indicated both Ni-P coatings were uniform and dense. The phosphorus content of Ni-P coating activated by the cobalt layer was 7.50%, which was lower than the phosphorus content of Ni-P coating activated by the traditional palladium layer (9.14%). The crystal structures of the Ni-P coatings on cobalt and palladium layers were characterized by XRD, and the two Ni-P coatings had a similar amorphous structure. There was an obvious broad peak between 44.4° and 51.6° could be indexed to the combination of (111) and (200) planes. The other weak and broad peaks at 76.1° and 92.1° could be indexed to (220) and (311) plane of nickel.
Figure 10 presents the XPS spectra of Ni-P coatings on cobalt layer and palladium layer obtained from alkaline electroless plating solution, and it can be found that the Ni2p and P2p fine spectra of Ni-P coating activated by cobalt and palladium layers are similar, indicating that the activation capacities of cobalt and palladium are equivalent. From the Ni2p fine spectra (Fig. 10a and Fig. 10c), it can be seen that most of the elemental nickel in the Ni-P coating corresponded to metallic nickel with binding energies of 852.00 eV and 869.1 eV, respectively. Also, the remaining two main peaks at 855.6 eV and 873.4 eV, respectively, as well as the nearby satellite peaks at 858.3 eV and 874.8 eV, indicated that other nickel-containing compounds were generated during the oxidation and phosphorylation of nickel in the alkaline Ni-P coating. The spectra of phosphorus (Fig. 10b and 10d) show that the peaks at 129.0 eV and 129.8 eV corresponded to P2p3/2 and P2p1/2 of phosphorus in the Ni-P plating, while the other peaks of phosphorus at ~ 132.4 eV were more heterogeneous, with a variety of phosphorus oxides produced during the electroless plating of Ni-P and the oxidation of the surface in air.
It can be seen from the cross-sectional morphology of Ni-P coatings on cobalt and palladium layers that all the coatings were compact and bonded well to the copper substrate. Both the Ni-P coatings obtained from the acidic electroless plating bath were thicker than the coatings obtained from the alkaline electroless plating bath. The Ni-P coating on cobalt layer obtained from acidic electroless plating bath had a thickness of 14.6 µm, which was smaller than the Ni-P coating on palladium layer with a thickness of 15.4 µm. The thickness of Ni-P coating on cobalt layer obtained from alkaline electroless plating bath (6.7 µm) was also lower than that of Ni-P coating on palladium layer under the same reaction conditions and reaction time. Although the smaller thickness of Ni-P coatings on cobalt layer suggested that the activation ability of cobalt layer was a littler weaker than that of palladium layer, cobalt layer could still serve as the activation layer to initiate electroless Ni-P plating.
3.3 Corrosion and tribological performance of Ni-P coating on cobalt and palladium layers
The corrosion resistance of Ni-P coatings on cobalt and palladium layers obtained from acidic and alkaline electroless plating bath were compared by electrochemical methods in 3.5 wt.% NaCl solutions. As shown in Fig. 12a, compared with Ni-P coating on palladium layer with the corrosion potential (Ecorr) of − 0.483 V and the corresponding corrosion current density (icorr) of 0.94 µA·cm− 2, the Ecorr of Ni-P coating on cobalt layer was decreased to − 0.519 V, and its icorr was increased to 1.63 µA·cm− 2. The corrosion resistance of Ni-P coating on cobalt layer was a little weaker than that of Ni-P coating on palladium layer. As shown in Fig. 12b, compared with Ni-P coating on palladium layer obtained from alkaline electroless plating bath with the corrosion potential (Ecorr) of − 0.568 V and the corresponding corrosion current density (icorr) of 1.64 µA·cm− 2, the Ecorr of Ni-P coating on cobalt layer was increased to − 0.564 V, and its icorr was decreased to 1.16 µA·cm− 2. The above results indicated that Ni-P coating on cobalt and palladium layer exhibited similar corrosion resistance, indicating that the activation ability of cobalt and palladium is comparable.
The dynamic friction coefficients of the Ni-P coatings measured in reciprocating mode are shown in Fig. 13a and 13b. From Fig. 13a, it can be seen from the friction curves of the acidic Ni-P coating activated by cobalt and palladium that the friction coefficients began stable after the 1000 s wear period, and the friction coefficient after stabilization was 0.178. The friction coefficients of the Ni-P coatings obtained from acidic bath were basically the same, indicating that cobalt and palladium had the same activation effect. From Fig. 13b, it can be seen that the friction curves of cobalt and palladium activated Ni-P coatings obtained from alkaline bath. The friction coefficient of cobalt activated Ni-P coatings remained stable throughout the friction period, and the friction coefficient after stabilization was 0.038. While the friction coefficient of palladium activated Ni-P coating increased slowly and steadily throughout the friction period. From Fig. 13c and 13d, it was obvious that the both cobalt and palladium activated Ni-P coating obtained from acidic bath was severely worn, and an obvious wide wear tract could be found. As can be seen from Fig. 13e and 13f, the wear of Ni-P coatings obtained from alkaline bath showed a smaller wear, and the wear tracks were narrow and discontinuous. Although the palladium activated Ni-P coating showed a little slighter were when compared with the cobalt activated Ni-P coating, the cobalt and palladium activated acidic and alkaline Ni-P coating had similar tribological performance.