Processing and properties of electrodeposited layered surface coatings

Hard chromium, produced by conventional dir ect curl ent (DC) electrodeposition, cannot be deposited to thicknesses gl enter than about 5 mu m because of the buildup of processing stresses which cause channel cracks in the coating. Much thicker chromium coatings map be produced by depositing a layered structure using alternate DC plating and periodic current reversal (PR). Such layering produces a through thickness stepped gradient in residual stresses. Most importantly a bending moment develops in the coating whenever the substrate is compliant. For thin, compliant substrates, the coating clacks and spalls off early on. For thick, non-compliant coatings, much thicker coatings can be formed. Fracture resistance must be considered in relation to both specimen and loading geometries. Since the inherent bending moment causes a maximum tensile stress at the coating surface, the loading geometry is almost always analogous to bending, and fracture resistance is provided through deviation of the channel crack by weak interfaces, resulting in 'terrace cracking'.