Influence of Silica Particle Size on the Corrosion Behavior of Electroplated Silica–Ni Hybrid Layer

[Image: see text] Silica–Ni hybrid layers were electroplated on a Q235 steel plate in a Watt nickel plating solution with varying sizes of silica, and a pure nickel layer was prepared as a blank sample. The surface morphology, composition, and crystal structure of the electroplated layers were examined using a field emission scanning electron microscope (FESEM), an energy-dispersive spectrometer (EDS), and a X-ray diffractor (XRD). The corrosion resistance of the samples was evaluated by the experiments of potentiodynamic polarization, electrochemical impedance spectroscopy, and salt spray test in NaCl solutions. The results showed that the smaller the particle size of silicon, the higher the content of silicon in the layer was, and the better the corrosion resistance of the layer was. However, when the particle size is 10 nm, agglomeration would happen, which leads to a decrease in the corrosion resistance performance, 50 nm silica–Ni hybrid layer showed the optimal corrosion resistance with the highest silica content.