Investigation of carbon fiber-reinforced composites through electroless nickel plating

The development of carbon fiber–reinforced composites (CFRCs) has significantly advanced material science by integrating high strength, low weight, and long-term durability into a single material system. In this study, electroless nickel (EN) plating was applied to carbon fiber rods to enhance their interfacial compatibility with the Al6061 alloy matrix fabricated through stir casting. Before plating, the fibers were cleaned, cut to size, sensitized, and activated before deposition under EN832 bath conditions. The treated fibers were then incorporated into molten Al6061 and solidified in preheated dies. Material characterization was carried out in accordance with ASTM standards, including density evaluation, Brinell and Vickers hardness testing, and pin-on-disc wear and friction analysis. Microstructural and compositional studies using SEM–EDX confirmed a uniform nickel coating with effective chemical distribution across the fiber surface. The Ni plating substantially improved wettability and interfacial adhesion, resulting in composites with higher hardness, improved strength, reduced density, lower coefficient of friction, and significantly enhanced wear resistance compared to unreinforced Al6061 alloy. An optimized nickel layer thickness provided strong bonding without compromising the integrity of the fibers. The objective of this study is to evaluate the influence of electroless nickel plating on interfacial bonding, mechanical behavior, and tribological performance of carbon fiber–reinforced Al6061 composites, and to establish its suitability for lightweight, highperformance engineering applications. The enhanced mechanical and tribological performance demonstrate that Ni-coated CF/Al6061 composites are promising candidates for aerospace, defense, automotive, and other advanced engineering industries.