Electrodeposited Co-P alloy and composite coatings: A review of progress towards replacement of conventional hard chromium deposits

Hard chromium coatings have attracted much attention due to their strong tribological and corrosion performance. There is a global need to replace such coatings in industrial applications owing to technical problems, environmental concerns and legislation. Co-P electrodeposits are a promising alternative to hard chromium in a variety of engineering applications due to their appreciable microhardness and high corrosion resistance. Attractive magnetic, tribomechanical and electrical properties are evident together with excellent thermal stability. Environmentally acceptable process conditions may be used which allow controlled deposition on diverse workpieces across a wide scale. This review provides an overview of the influence of operational parameters, including type of current control, electrolyte composition, pH, current density and electrolyte agitation on the physicochemical and mechanical characteristics of the deposits. The incorporation of ceramic particles into Co-P electrodeposits to produce tailored composite coatings is also considered. An insight is given into the development of next generation alloy and composite deposits to replace hard chromium deposits from acidic Cr(VI) baths. Diverse applications for Co-P electrodeposits are considered and topics deserving further R & D are highlighted.