Abstract
Electrodeposited zinc and zinc-alloy coatings have been extensively used in a wide variety of applications such as transport, automotive, marine, and aerospace owing to their good corrosion resistance and the potential to be economically competitive. As a consequence, these coatings have become the industry choice for many applications to protect carbon and low alloy steels against degradation upon their exposure in different corrosive environments such as industrial, marine, coastal, etc. Significant works on the electrodeposition of Zn, Zn-alloys and their composites from conventional chloride, sulfate, aqueous and non-aqueous electrolyte media have been progressed over the past decade. This paper provides a review covering the corrosion performance of the electrodeposited Zn, Zn-alloy and composite with different coating properties that have been developed over the past decade employing low-toxic aqueous and halide-free non-aqueous electrolyte media. The influence of additives, nano-particle addition to the electrolyte media on the morphology, texture in relation to the corrosion performance of coatings with additional functionalities are reviewed in detail. In addition, the review covers the recent developments along with cost considerations and the future scope of Zn and Zn-alloy coatings.
Highlights
The authors attributed the enhancement in corrosion resistance to the texture, morphology obtained with the acetate-based electrolyte and demonstrated its techno-commercial capability to replace the currently used electrolytes
It is well known that Zn coatings are prone to atmospheric corrosion and result in the impart the necessary additional properties such as superhydrophobicity, improved hardness, wear formation of different corrosion products depending on the nature of environment they resistance, fouling resistance of mild steel components
The formation of porous or a compact ZnO layer either at the bottom or intermediate remains critical for the electrodeposited Zn, Zn-alloy metal structures and their composites fabricated using the less toxic citrate, acetate baths and Ionic liquids (ILs) used in a marine environment
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. An ideal coati resistance of ferrous steel materials such as mild steel, environmental low alloy steels, etc.threat These coatings protect the metal structures by acting either as a physical barrier or as a selection of metal and its alloys as preferred coating material can be considered as a mi sacrificial coating [12]. Such a transition during the initial period of studies (between 1 to 3 years) are reported to be uneven and can occur either sooner or later depending on the presence of certain aggressive constituents (such as carbon dioxide, chloride, sulphates, nitrates), and their relative concentrations Considering such a scenario, conducting long-term corrosion studies of Zn/Zn–alloy protective coatings under atmospheric conditions deserve significant attention [20] as they provide information on the corrosion products, processes and their formation mechanisms on the coated surface. This review will cover the progress on the recent developments in Zn, Zn–alloy, composite coatings, electrodeposited on different commonly used industrial substrates and their corrosion performance along with future challenges and economics
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