Nanocrystalline Soft Ferromagnetic Ni Co P Thin Film on Al
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Applied Surface Science 254 (2008) 1966–1971
Nanocrystalline soft ferromagnetic Ni–Co–P thin film on
Al alloy by low temperature electroless deposition
A. Abdel Aal *, A. Shaaban, Z. Abdel Hamid
Central Metallurgical Research & Development Institute (CMRDI), P.O. 87 Helwan, Cairo, Egypt
Received 24 May 2007; received in revised form 5 August 2007; accepted 5 August 2007
Available online 14 August 2007
Abstract
Soft ferromagnetic ternary Ni–Co–P films were deposited onto Al 6061 alloy from low temperature Ni–Co–P electroless plating bath. The
effect of deposition parameters, such as time and pH, on the plating rate of the deposit were examined. The results showed that the plating rate is a
function of pH bath and the highest coating thickness can be obtained at pH value from 8 to10. The surface morphology, phase structure and the
magnetic properties of the prepared films have been investigated using scanning electron microscopy (SEM), X-ray diffraction analysis (XRD) and
vibrating magnetometer device (VMD), respectively. The deposit obtained at optimum conditions showed compact and smooth with nodular grains
structure and exhibited high magnetic moments and low coercivety. Potentiodynamic polarization corrosion tests were used to study the general
corrosion behavior of Al alloys, Ni–P and Ni–Co–P coatings in 3.5% NaCl solution. It was found that Ni–Co–P coated alloy demonstrated higher
corrosion resistance than Ni–P coating containing same percent of P due to the Co addition. The Ni–Co–P coating with a combination of high
corrosion resistance, high hardness and excellent magnetic properties would be expected to enlarge the applications of the aluminum alloys.
# 2007 Published by Elsevier B.V.
Keywords: Electroless Ni–Co–P; Ferromagnetic coatings; Thin films; Al alloy
1. Introduction
The progress in superior soft magnetic materials and films is
the key for making high performance data storage devices. Ni–
Co–P films are generally used as magnetic recording media for
electronic computers and as diffusion barriers [1]. The develop-
ment of soft magnetic materials with improved performance is
considered to be one of the most important features in the field of
information technology. Recently, binary and ternary soft mag-
netic alloys such as Co–Ni, Ni–Fe, Co–B, Co–Fe–B, Co–Ni–P,
are being developed for potential applications in modern high
density recording and data storage discs [2,3]. These soft mag-
netic materials are incorporated in the induction recording heads
for writing bit information onto hard disks for several years [4].
Nowadays, nanostructured soft magnetic films have been
effectively used to construct multilayer structures that exhibit
* Corresponding author at: Surface Protection & Corrosion Control Lab,
Central Metallurgical Research & Development Institute (CMRDI), P.O. 87
Helwan, Cairo, Egypt. Tel.: +20 122690782; fax: +20 225010639.
E-mail address: [email protected] (A.A. Aal).
0169-4332/$ – see front matter # 2007 Published by Elsevier B.V.
doi:10.1016/j.apsusc.2007.08.017
giant magnetoresistive (GMR) behavior [5]. Soft magnetic thin
films can be used in several functional micro-electromechanical
system (MEMS) devices such as, magnetic microactuators,
sensors and micromotors [6].
Magnetic thin films can be deposited by several techniques
such as physical vapor deposition (PVD) processes using dc or
radio frequency sputtering [7,8] and wet methods by
electrochemical or electroless technique [9,10]. However,
electroless deposition method can be considered more suitable
than electrolytic one due to the possibility of achieving uniform
surface coverage and plating micromagnetic patterns on variety
of substrates [11]. The autocatalytic electroless can usually be
achieved at high temperature (60–90 8C) [12]. Besides, it can
be performed at lower temperature (35 � 1 8C) that enables to
reduce the energy requirements and facilitate the controlling of
solution composition and deposition parameters [13,14]. In this
perspective, the present work aims to study the formulation and
development of Ni–Co–P electroless plating bath that operate
at relatively low temperature, the deposition of electroless
Ni–Co–P coatings using such bath and evaluation of coating
characteristics such as corrosion behavior and magnetic
properties.
A.A. Aal et al. / Applied Surface Science 254 (2008) 1966–1971 1967
2. Experimental procedures
2.1. Materials and Ni–Co–P deposition
Al 6061 alloy with chemical composition (1.0% Mg, 0.6%
Si, 0.28% Cu, 0.2% Cr and rest Al) was used as a substrate.
Electroless Ni–Co–P deposition on Al alloy usually requires a
series of pre-treatment steps to ensure good quality deposits.
The pre-treatment series starts by degreasing in order to remove
soaks, lubricants and fingerprints followed by acidic etching.
Then the main step is the zincate treatment which applied to
remove the oxides and deposits a protective zinc layer. It is
usually necessary to repeat this process to obtain the best
quality converging [15].
For electroless of Ni–Co–P deposition bath, NiSO4�6H2O
and CoSO4�6H2O were used as the source of nickel and cobalt,
respectively. NaH2PO2�H2O was used as a reducing agent,
which also forms the source of phosphorus in the deposit.
Na3C6H5O7 was used as the complexing agent to control the
rate of release of free metal ions for the reduction reaction. In
addition to other constituents, ammonia solution was added to
control the bath pH and the bath was operated at a constant
temperature 35 � 1 8C during the deposition process. The pre-
treatments, the bath composition and operating conditions
employed for preparation are given in Table 1.
2.2. Analysis
The electrolessed Ni–Co–P deposit was stripped in 10%
HNO3 and the dissolved metal (Co, P and Ni) was determined
Table 1
The bath composition and operating conditions of electrolessed Ni–Co–P film for
Process Composition
1 Mechanical polishing 600# emery paper then,
380# alumina sand paper
2 Alkaline degreaser Na2CO3
Na3PO4
NaOH
3 Acidic etching HNO3:HF:H2O 9:2:1, v/v
4 Zincate solution NaOH
ZnO
FeCl3KNa-tartrate
Na3N
5 Zincate removal HNO3
6 Re-zincate solution NaOH
ZnO
FeCl3KNa-tartrate
Na3N
7 Electroless Ni–Co–P NiSO4�6H2O
CoSO4�6H2O
NaH2PO2�H2O
Na3C6H5O7
H3BO3
by atomic absorption technique using Perkin-Elmer, Atomic
Absorption Model, A Analyst 200. The morphology was
observed using scanning electron microscopy (JEOL-JSM-
5410) before and after heat treatment, respectively. Vicker’s
microhardness measurements were carried out using a tukon
series B200 microhardness tester with loads of 100 g and
indentation time 10 s. The hardness values were measured as
average along the specimen surface. The mean hardness of five
readings was calculated for every specimen.
Potentiodynamic polarization corrosion tests were used to
study the general corrosion resistance of the samples (Al
alloy, as-deposited Ni–Co–P) at room temperature using an
Auto lab1 Pgstate 30 with corrware software. The
electrochemical measurements were made in a conventional
three-electrode cell using a saturated calomel electrode
(SCE) as a reference electrode and a platinum rod as a
counter electrode. After the electrochemical testing system
was stable, the measurements were carried out in 3.5% NaCl
solution. Potentiodynamic polarization curves of the tested
samples were obtained and corrosion rates were determined
for comparison. For comparison, the corrosion tests have
been applied for Ni–P coatings containing the same percent
of P.
The magnetic properties of electroless Ni–Co–P ternary
alloy deposits were studied using a vibrating magnetometer
device (9600-VSM) at an applied field of 5 KOe. The magnetic
properties, viz. saturation magnetization Ms, remanence Mr,
coercivety Hc and the squareness S derived from the hysteresis
loop perpendicular to the film surface with 5 kOe magnetic
field.
mation onto aluminum alloys sequences
Operating conditions
–
32 g/l Time, 2 min, temperature, 50 8C32 g/l
1.5 g/l
Time, 1 min room temperature
525 g/l Time, 1–3 min room temperature
10 g/l
10 g/l
10 g/l
1 g/l
50%, v/v Time, 0.5 min room temperature
525 g/l Time, 0.5 min room temperature
10 g/l
10 g/l
10 g/l
1 g/l
7 g/l pH 8–11
22 g/l Time, 15–65 min
25 g/l Temperature, 35 � 1 8C50 g/l
30 g/l
Fig. 1. Effect of deposition time and pH on the coating thickness of electroless Ni–Co–P ternary film deposition.
Fig. 2. XRD patterns of (a) coated Ni–Co–P and (b) annealed Ni–Co–P films.
A.A. Aal et al. / Applied Surface Science 254 (2008) 1966–19711968
3. Results and discussion
3.1. Effect of pH and deposition time on the coating
thickness
The effect of the bath pH on the coating thickness of
electroless Ni–Co–P alloys deposit is depicted in Fig. 1a. It is
evident that at lower pH values (pH<8), the deposition process
is characterized by instability of the bath producing irregular
and poor deposits. An increase in the bath pH from 8 to 10 was
found to increase the coating thickness with formation of bright
and adherent deposits. However, at higher pH values (pH>10),
the bath decomposes and the coating thickness drastically
decreases. It was reported previously that OH� ions
concentration increases with pH increasing in range of 8–10
and the hypophosphite oxidation is the dominant factor in the
electroless process [16]. In alkaline media, the oxidation of
hypophosphite reaction occurs as follows:
H2PO2� þ 3OH� $ H2PO3
�2þ 2H2O þ 2e� (1)
From the above chemical reaction, an increase in bath pH
value leads to increasing in the oxidation rate of hypophosphite
which in turn accelerates the plating rate. However, the
solutions become unstable at higher pH, especially above pH
11.0 where nickel and cobalt hydroxides will precipitate during
the deposition process. Hence, higher values of pH were not
recommended because of hydroxides precipitation and also
because of the microelectronic industry requirements for circuit
preservation [17]. In conclusion, it is preferable to use the bath
approximately pH 9.5, where there is a good coating thickness
as well as the stability of the bath.
The variation of coating thickness with the deposition time is
illustrated in Fig. 1b. It can be seen that the coating thickness
increases with the processing time. This can be ascribed to the
autocatalytic nature of the electroless plating process. However,
the relationship between time and coating thickness is not linear
due to the build-up of orthophosphite ions by oxidation of
sodium hypophosphite in Eq. (1). The quantitative analysis of
Ni–Co–P deposit showed that the contents of Ni, Co and P in
the film are 60, 15 and 25 wt.% for, respectively.
3.2. Phase structure and surface morphology
Fig. 2 shows X-ray diffraction patterns of electrolessed Ni–
Co–P deposits before and after annealing at 400 8C for 2 h.
XRD pattern of Ni–Co–P as-deposited (without annealing)
shows peaks of hcp-Co, fcc-Ni and metastable bcc-Ni7P3
phases. The appearance of Ni7P3 is attributed to the higher
phosphorous segregation in grain boundary regions. On the
other hand, for the annealed samples, new peaks of stable bct-
Ni3P phase are observed at 36.58, 41.78 and 46.68 in addition to
hcp-Co and fcc-Ni peaks. The higher intensity for annealed
samples pattern indicates to the higher degree of crystallinity in
these samples. During the annealing process, the higher
phosphorous regions were supposed to be further increased by
A.A. Aal et al. / Applied Surface Science 254 (2008) 1966–1971 1969
extraction of P dissolved in nickel grains which in turn gave rise
to precipitation of the hard inter-metallic Ni3P phase. These
transformations support the earlier observation obtained by
Sankara et al. [18] and Hur et al. [19].
The surface morphology of the Ni-Co–P layer before and
after annealing is shown in Fig. 3. The deposit obtained at
optimum conditions (pH 9.5 and deposition time 15 min) was
compact and smooth with nodular grains as shown in Fig. 3a.
The observed randomness in distribution of spherical nano-
particles with size in the range 150–250 nm is due to the
partially amorphous structure in Ni–Co–P film grown in
perpendicular direction to the substrate surface. Fig. 3b shows
SEM of Ni–Co–P coating after annealing at 400 8C for 2 h. It
can be observed that there is no significant change in the
crystallite size after annealing process. However, the crystal
structure and the phase were converted from bcc-Ni7P3 into bct-
Ni3P as shown in the XRD pattern (Fig. 2b). This transforma-
tion in crystal structure is attributed to two reasons. Firstly, the
deposit components and substrate, which have different thermal
expansion coefficients, undergo different volume changes due
to a temperature change by annealing. The evolution of texture
during annealing of electroless Ni–Co–P has been studied
previously by Lee and Hur [20]. The strains and stresses due to
the different thermal expansion coefficients are calculated by
the integral equation:
eth ¼Z T
T0
ðas � afÞ dT (I)
Fig. 3. SEM images of Ni–Co–P films (pH 9.5 and deposition time 15 min).
where T and a are temperature and thermal expansion coeffi-
cient, respectively. Subscripts 0, s and f indicate initial state,
substrate and film, respectively. Setting T = 400 8C, T0 = 35 8C,
as = aAl = 25.8 � 10�6 K�1, af = aNi = 13.3 � 10�6 K�1 and
the eth = 12.5 � 10�6. For more accuracy, the thermal expan-
sion coefficients of fcc-Ni–Co solid solutions should be used.
The thermal expansion coefficient of cobalt (hcp) is
13.8 � 10�6 K�1 [21], which is very close to that of nickel.
Therefore, the closed thermal expansions of these components
explain why the coating is not exposed to the delamination
during the annealing process. In addition, the formation of
nickel phosphide could lead to volume changes [20].
Secondly, Ni–Co–P film tensile stress (which attributed to
the high phosphorus content) is relieved after annealing
process, so the lattice parameter of bcc is contract in one
dimension along (c-axis) from 8.643 to 4.386 A and the other
lattice parameters a, b almost still constant to form bct crystal
structure.
3.3. Hardness measurements
The microhardness of Al alloy, as-deposited film and
annealed one has been measured by Vicker’s method. The
hardness of Al alloy increased from 66 � 5 to 287 � 5 HV100 g
after coating. It was found that the microhardness of Ni–Co–P
deposits enhanced after annealing (400 8C for 2 h) up to
520 � 5 VH100 g. Such improvement of the microhardness after
annealing can be attributed to the formation of Ni3P inter-
metallic phase which generated the effect of precipitation
hardening [22].
3.4. Corrosion and polarization measurements
Electrochemical potentiodynamic polarization experiment
was applied in a 3.5% NaCl solution in order to measure the
corrosion resistances of Al alloy and as-deposited Ni–Co–P
coating. For comparison, the corrosion properties of Al alloy
coated by Ni–P, deposited from standard bath and containing
the same content of P, have been studied (Fig. 4). The
Fig. 4. Potentiodynamic curves for (a) uncoated Al alloy and coated by (b) Ni–
P and (c) Ni–Co–P tested in 3.5% NaCl.
Table 2
Electrochemical corrosion data related to polarization curves of uncoated Al alloy and coated by Ni–P and Ni–Co–P tested in 3.5% NaCl solution
Sample ba bc Rp (V/cm2) Icorr (mA/cm2) Ecorr (V) Cr (mpy)
Uncoated alloy 0.062 0.032 129 71.1 �0.733 30.81
Ni–P coating 0.031 0.042 287 27.2 �0.657 11.52
Ni–Co–P coating 0.005 0.077 370 5.5 �0.595 2.38
A.A. Aal et al. / Applied Surface Science 254 (2008) 1966–19711970
electrochemical parameters obtained from the polarization
curves for uncoated Al alloy and the coated alloy by Ni–Co–P
and Ni–P are displayed in Table 2.
The corrosion potential of the Al alloy is �0.733 V, which
is higher than that of Ni–P (�0.657 V) and Ni–Co–P coated
alloy (�0.593 V). On the contrary, the corrosion current
densities of Ni–P and Ni–Co–P coated Al alloys are 5.5 and
27.2 mA/cm2, which are somewhat lower than that of
uncoated Al alloy 71.1 mA/cm2. The polarization resistance
(Rp) of Al, Ni–P and Ni–Co–P coated alloys are 129, 287 and
370 V/cm2, respectively. It is evident that the Ni–Co–P
coating layer provides effective protection for Al alloy than
Ni–P coating. Therefore, the corrosion current Icorr values can
be calculated by using the Stearn–Geary equation with
Ozyilmaz et al. [23].
Icorr ¼b
RP
(II)
where b is constant value calculated by the following equation:
b ¼ babc
2:3ðba þ bcÞ(III)
where ba and bc are anodic and cathodic Tafel slopes that were
obtained from polarization curves. The value of b were 0.009,
0.007, 0.002 V for Al alloy, Ni–P and Ni–Co–P coated alloys.
Corrosion potential Ecorr is obtained using Tafel extrapolation
method and corrosion rate is calculated from the following
equation:
Corrosion rate ðmpyÞ ¼ 0:13Icorrðeq: wt:Þd
(IV)
where (eq. wt.) is the equivalent weight in gram and d is the
density in g/cm3 of Al alloy (for uncoated samples) or of Ni (for
coated samples). Therefore, the corrosion rates of uncoated,
Fig. 5. The hysteretic behavior of (a) coate
Ni–P and Ni–Co–P coated Al alloys in 3.5% NaCl solution can
be estimated from Icorr and the Faraday’s law, which are 30.81,
11.52 and 2.38 mpy, respectively.
The enhancement in corrosion resistance by Ni–P and
Ni–Co–P deposits is due to the formation of an adsorbed
layer of hypophosphite anion H2PO2� on the surface of
coatings could provide passivity in aqueous environment
[24]. Flis and Duquette reported that phosphorous is enriched
on the surface layer by the preferential dissolution of nickel
[25]. Then, the passive barrier layer of H2PO2� is formed
by reaction of the enriched P with water. By this way,
H2PO2� layer will block the supply of water to the electrode
surface and prevent the hydration of nickel, which is
considered to be the first step to form either soluble Ni+2
species or a passive nickel film. Generally, it can be
concluded that the improved corrosion resistance obtained
for electroless Ni–Co-P and Ni–P coatings is due to the
enrichment of phosphorous on the electrode surface [26].
Therefore, a conclusion can be drawn that the presence of Co
in Ni–P amorphous deposits improves their corrosion
resistance as obtained previously by Parent et al. [27]. Such
corrosion resistance improvement can be attributed to the
more compact passive film in Ni–Co–P coatings based on
anodic polarization and impedance tests [27].
3.5. Magnetic properties
The magnetic properties of as-plated electroless Ni–Co–P
before and after annealing have been studied using a vibrating
magnetometer device by applying a magnetic field of 5 KOe
perpendicular to the sample surface. The hysteresis loops of
investigated samples are shown in Fig. 5. It can be seen that
the hysteresis loops shapes for both of coated and annealed
samples are narrow and curved. This shape seems to be very
d Ni–Co–P and (b) annealed Ni–Co–P.
Table 3
Magnetic parameters of electroless Ni–Co–P ternary alloy deposits
Sample Mr (emu/g) Ms (emu/g) Hc (Oe) HK (Oe) S
Coated alloy 2.15 25.8 36.5 1194 0.08
Annealed alloy 3.24 23.2 96.3 1196 0.14
A.A. Aal et al. / Applied Surface Sc
similar to that exhibited by partially or totally amorphous
materials and by an amorphous Ni–Co–P film [28,29]. It can
be mentioned that the prepared electroless Ni–Co–P thin film
of the present study have an amorphous structure with soft
magnetic characteristics. The coercivety Hc of annealed Ni–
Co–P film is affected not only by the grain size but also by
impurities and variation of magnetic anisotropy energy
governed by shape, film stress and crystalline anisotropy.
Although SEM images showed no significant change in grain
size of Ni–Co–P film before and after annealing, the
coercivety was higher for the annealed ones. This behavior
can be attributed to the increasing of the magnetoelastic
anisotropy in the film after stress relief due to the annealing
process [30].
The magnetic properties, viz. saturation magnetization
Ms, remanence Mr, coercivety Hc and the squareness S of
the Ni–Co–P thin film were derived from the hysteresis
loops. The data are summarized in Table 3. It was noticed
that both of coated and annealed samples exhibited soft
ferromagnetic behavior. Besides, there is no appreciable
change in either magnetic properties or the hysteretic
behavior by annealing except the increasing in coercivety
Hc and the squareness S from 36.5 to 96.3 Oe and from 0.08
to 0.14, respectively.
4. Conclusions
- Electrolessed Ni–Co–P films have been deposited onto Al
alloy with nanocrystallite sizes in 150–250 nm range.
- T
he coating thickness is dependent of plating parameters (pHand deposition time).
- T
he optimum bath pH and deposition time are of 9.5and 15 min, respectively, where there are the highest
coating thickness (0.92 mm) as well as the stability of the
bath.
- T
he Ni–Co–P films showed short-range order without grainboundaries forming an amorphous phase. However, after
annealing (at 400 8C for 2 h), the degree of crystallinity
increases and the microhardeness is improved.
- T
he presence of Co in Ni–P film improves the corrosionresistance of Al alloy.
- T
he Ni–Co–P coating with a combination of high corrosionresistance and high hardness would be expected to enlarge the
applications of the aluminum alloys.
- T
he coated and annealed Ni–Co–P films deposited ontoAl alloys exhibit excellent magnetic recording media
properties.
Acknowledgements
Help received from both of Dr. W. Agami (Ain Shams
University) and F. Abdel Mouez (CMRDI) during the course of
this work is greatly acknowledged.
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