The current study focuses on the parametric optimization of electroless Ni-Co-P coating considering surface roughness as a response using Box-Behnken Design (BBD) of experiment. The two bath parameters namely the concentration of cobalt sulphate and sodium hypophosphite were varied along with the bath temperature to predict the variation in surface roughness. Analysis of variance (ANOVA) method has been applied to determine the interactions of the substantial factors which dominate the surface roughness of the coating. The process parameters for surface roughness of the coating were optimized by successfully utilizing the statistical model of Box-Behnken Design (BBD) of experiment. From the BBD model, the optimum condition for the deposition of the coating has been evaluated. In that specific condition, the surface roughness of the as-deposited coating is found to be 0.913μm. Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDX), and X-Ray Diffraction (XRD) study have been utilized to characterize the electroless Ni-Co-P coating deposited in optimized condition.

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Ternary Ni-Co-P alloy coating was chosen to improve the corrosion resistance of the Copper substrate. Box-Behnken Design (BBD) of experiment was utilized for the optimization of the effects of different process parameters such as Cobalt Sulphate, Sodium Hypophosphite, and temperature. Electrochemical Impedance Spectroscopy (EIS) was used to study the corrosion resistance behaviour of different samples by altering different parameters. Analysis of Variance (ANOVA) was done to determine the important process parameters and their significant interactions. The surface morphology, microstructures and elemental compositions of the as-deposited coatings were analyzed using Scanning Electron Microscopy (SEM), X-Ray Diffraction (XRD) and Energy Dispersive X-Ray Spectroscopy (EDX) respectively. Finally, 15g/L of Cobalt Sulphate, 25g/L of Sodium Hypophosphite, and 85°C of bath temperature were found out to be the optimum conditions for coating deposition in order obtain a corrosion resistance of 1165 ohm-cm2.

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