Electrical characterization of Thick coating of Barium Calcium Zirconium Titanate on Nickel Substrate.

Electrophoretic Deposition Technique is employed for the preparation of thick coatings having applications in microelectromechanical systems (MEMS), energy harvesting, thin-layered sensors, actuators, and microelectronic industries. Barium Calcium Zirconium Titanate (Ba0.85Ca0.15)(Zr0.1Ti0.9)O3 (BCZT) was synthesized by the solid-state route and coated on nickel substrates possessing a face-centered cubic (FCC) structure. The coated samples were sintered at 1115°C for 30 min. Structural confirmation of BCZT coatings was carried out using X-ray diffraction (XRD), while surface morphology was investigated through scanning electron microscopy (SEM). Optical microscopy coupled with ImageJ analysis revealed a coating thickness of approximately 54 µm, which increased with deposition time and applied voltage. Atomic force microscopy (AFM) was employed to evaluate the surface roughness and topographical features of the coatings. Electrical conductivity measurements performed between 300°C and 400°C demonstrated enhanced conductivity with increasing temperature and frequency. Impedance spectroscopy (IS) in the frequency range of 100 Hz–1 MHz indicated a negative temperature coefficient of resistance (NTCR) behavior. The obtained Bode and Nyquist plots exhibited characteristic semicircular responses, confirming the potential of BCZT thick coatings for high-temperature and high-energy applications. Therefore, these BCZT coatings demonstrate promising multifunctional properties, making them suitable for advanced device integration in harsh environments, particularly in high-temperature sensing, energy harvesting systems, and next-generation microelectronic applications.