Metals and alloys containing Al, Ti, Zr and Nb are difficult-to-plate upon materials due to presence of tenacious oxide layer on their surface. These oxide layers prevent metallic bond formation between substrate and the deposited metallic coating while aqueous plating resulting into peeling/flaking off coating. However, such metals and alloys require corrosion/erosion resistant coating for variety of functional and demanding applications. The process developed here to remove such oxide layers in-situ by adopting suitable chemical/electrochemical surface engineering approach and then deposition of Nano-Ni interlayer coating. Post plating, a suitable heat-treatment was given to improve mechanical properties of the Nano-Ni coating.

1. Nano-Ni coating is highly corrosion, erosion and wear resistant coating.
2. This coating process is inexpensive and easy scalable to large scale production.
3. It produces highly adherent uniform thickness coating all across the surfaces even in intricate geometries unlike electroplating.
4. Nano-Ni coating with phosphorous content in the range 1-3 wt% can be produced.
5. Nano-Ni coating with microhardness in the range 700-900 HV100gf can be produced.
6. Successfully passed 64 h ASTM B368 CASS test for corrosion resistance without any corrosion spot.

1. Nano-Ni coating find applications in automobile industry, aerospace industry, nuclear industry and metal finishing industry.

Metals and alloys containing Al, Ti, Zr and Nb are difficult-to-plate upon materials due to presence of tenacious oxide layer on their surface. These oxide layers prevent metallic bond formation between substrate and the deposited metallic coating while aqueous plating resulting into peeling/flaking off coating. However, such metals and alloys require corrosion/erosion resistant coating for variety of functional and demanding applications. The process developed here to remove such oxide layers in-situ by adopting suitable chemical/electrochemical surface engineering approach and then deposition of Nano-Ni interlayer coating. Post plating, a suitable heat-treatment was given to improve mechanical properties of the Nano-Ni coating.

1. Nano-Ni coating is highly corrosion, erosion and wear resistant coating.
2. This coating process is inexpensive and easy scalable to large scale production.
3. It produces highly adherent uniform thickness coating all across the surfaces even in intricate geometries unlike electroplating.
4. Nano-Ni coating with phosphorous content in the range 1-3 wt% can be produced.
5. Nano-Ni coating with microhardness in the range 700-900 HV100gf can be produced.
6. Successfully passed 64 h ASTM B368 CASS test for corrosion resistance without any corrosion spot.

Nano-Ni coating find applications in

1. Automobile industry
2. Aerospace industry
3. Nuclear industry
4. Metal finishing industry

1. Raw materials are easily available in the local market.

1. The process developed requires simple plating set-up consisting of plating tank, DC power supplier, continuous filtration unit attached with pump, Dm water system (30 L/day) vacuum furnace for heat-treatment, weighing balance, heating cum stirring unit, air purging facility.

1. The manpower requirements depend on the capacity and the extent of automation. However, one Chemist (B.Sc.)& two technicians are sufficient to start production.