Designing nickel coatings for water erosion performance: optimisation of grain size and thickness

Nithin Chandra Gaddavalasa; Arijit Lodh; Andrea Cini; Vinodhen Saaran; Ali Mehmanparast; Andrew Starr; Gustavo M. Castelluccio

doi:10.1016/j.engfailanal.2025.109564

Designing nickel coatings for water erosion performance: optimisation of grain size and thickness

Nithin Chandra Gaddavalasa, Arijit Lodh^*, Andrea Cini, Vinodhen Saaran, Ali Mehmanparast, Andrew Starr, Gustavo M. Castelluccio

^*Corresponding author for this work

Naval Architecture, Ocean And Marine Engineering

Research output: Contribution to journal › Article › peer-review

Abstract

Metallic coatings are gaining interest as an alternative to classical polymeric layers for erosion damage prevention due to their extended durability and sustainability. However, their implementation requires a thorough understanding of protective potential and reliability. This study explores the use of brush-plated nickel coatings on carbon-fibre reinforced composites to enhance their performance against water erosion. A combination of experimental analysis and computational modelling explores the effect of different coating thickness and properties to withstand water droplet erosion damage. Findings reveal a minimum critical coating thickness around 40 μ m can significantly improve the erosion resistance.

Original language	English
Article number	109564
Journal	Engineering Failure Analysis
Volume	175
Early online date	8 Apr 2025
DOIs	https://doi.org/10.1016/j.engfailanal.2025.109564
Publication status	E-pub ahead of print - 8 Apr 2025

Funding

We wish to acknowledge the support of the Henry Royce Institute for advanced materials through the Materials Challenge Accelerator Programme, funded from a grant provided by the Engineering and Physical Sciences Research Council (EP/X527257/1).

Keywords

Rain erosion
Composite
Electrodeposition
Nickel coatings

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title = "Designing nickel coatings for water erosion performance: optimisation of grain size and thickness",

abstract = "Metallic coatings are gaining interest as an alternative to classical polymeric layers for erosion damage prevention due to their extended durability and sustainability. However, their implementation requires a thorough understanding of protective potential and reliability. This study explores the use of brush-plated nickel coatings on carbon-fibre reinforced composites to enhance their performance against water erosion. A combination of experimental analysis and computational modelling explores the effect of different coating thickness and properties to withstand water droplet erosion damage. Findings reveal a minimum critical coating thickness around 40 μ m can significantly improve the erosion resistance.",

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T2 - optimisation of grain size and thickness

AU - Gaddavalasa, Nithin Chandra

AU - Lodh, Arijit

AU - Cini, Andrea

AU - Saaran, Vinodhen

AU - Mehmanparast, Ali

AU - Starr, Andrew

AU - Castelluccio, Gustavo M.

PY - 2025/4/8

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N2 - Metallic coatings are gaining interest as an alternative to classical polymeric layers for erosion damage prevention due to their extended durability and sustainability. However, their implementation requires a thorough understanding of protective potential and reliability. This study explores the use of brush-plated nickel coatings on carbon-fibre reinforced composites to enhance their performance against water erosion. A combination of experimental analysis and computational modelling explores the effect of different coating thickness and properties to withstand water droplet erosion damage. Findings reveal a minimum critical coating thickness around 40 μ m can significantly improve the erosion resistance.

AB - Metallic coatings are gaining interest as an alternative to classical polymeric layers for erosion damage prevention due to their extended durability and sustainability. However, their implementation requires a thorough understanding of protective potential and reliability. This study explores the use of brush-plated nickel coatings on carbon-fibre reinforced composites to enhance their performance against water erosion. A combination of experimental analysis and computational modelling explores the effect of different coating thickness and properties to withstand water droplet erosion damage. Findings reveal a minimum critical coating thickness around 40 μ m can significantly improve the erosion resistance.

KW - Rain erosion

KW - Composite

KW - Electrodeposition

KW - Nickel coatings

U2 - 10.1016/j.engfailanal.2025.109564

DO - 10.1016/j.engfailanal.2025.109564

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VL - 175

JO - Engineering Failure Analysis

JF - Engineering Failure Analysis

M1 - 109564

ER -

Designing nickel coatings for water erosion performance: optimisation of grain size and thickness

Abstract

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Keywords

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