Ni-W-Al2O3 composite coatings was successfully prepared on 45# steel substrate by electrochemical deposition technique in Ni-W electrolytic plating bath containing Al2O3 particle. Al2O3 particles were dispersed by chemical methods in advance with some surfactants such as sodium lauryl sulfate and 1.4 butynediol under different fields respectively to further improve the wear resistance of Ni-W-Al2O3 composite coatings. The surface and wear track morphology of Ni-W-Al2O3 composite coatings were characterized by scanning electron microscopy (SEM) and energy dispersed spectroscopy (EDS). Furthermore, wear loss and wear rate were investigated by friction and wear testing machine, and three-dimensional surface profile, and compared with the friction and wear performance of composites each other. The results showed that the composite coatings with adding Al2O3 particles which were dispersed by surface-active agent of 1.4 butynediol exhibited excellent abrasion performance and optimal wear resistance. Compared with the composite coating with adding non-dispersed Al2O3 particle, the wear resistance nearly increased four times in same circumstances, and the minimum wear rate was 2.51×10-6 mm3·(N·m)-1. In addition, the wear rate of composite coating decreased by 24.0% and 34.8% compared with adding Al2O3 particle of non-dispersed under static magnetic and ultrasonic field, respectively. The microstructure results showed that the surface morphology of coatings exhibited good compact and uniformity structure, pinhole and defects were also significantly reduced and even disappeared with Al2O3 dispersion of 1.4 butynediol under corresponding field, but during the process of ultrasonic wave field, the grains grew obviously. © Editorial Office of Chinese Journal of Rare Metals. All right reserved.
