Electroforming of Ni–P–PTFE Nanocomposites with Nanoscale Surface Roughness and Superior Self-Lubricating Properties

The electrodeposition of Ni–P–PTFE nanocomposites offers an effective approach to reduce mold–polymer interface adhesion and improve the replication of polymer micro features in injection molding. However, it is still challenging to fabricate Ni–P–PTFE nanocomposites with low internal stress and nanoscale surface roughness in electrolytes containing high PTFE concentrations. In this study, cetyltrimethylammonium bromide was introduced into the electrolytes to achieve a good dispersion of PTFE nanoparticles. Ni–P–PTFE nanocomposites with various compositions were successfully electrodeposited, and their tribological properties were analyzed. The electroformed Ni–P–PTFE nanocomposites with high PTFE and phosphorus contents showed a low surface roughness and surface energy compared to nickel electrodeposits. Ni–P–PTFE nanocomposites also exhibited a low coefficient of friction (COF) and wear loss when electroformed from an electrolyte containing 32 g/L phosphorus acid and 5 g/L PTFE nanoparticle. The COF of Ni–P–PTFE against stainless steel and poly(methyl methacrylate) was 0.2 and 0.12, respectively, representing a decrease of 80% and 85% compared to nickel electrodeposits. These enhancements in self-lubricating performances were primarily attributed to the low surface roughness and a shift in wear modes from adhesive wear to predominantly mild abrasive wear.