Abstract
The effects of zinc and sodium hydroxide concentrations in an alkaline non-cyanide zinc bath on the electrodeposition characteristics of zinc deposits are systematically investigated. Using microstructural and phase analyses of specimens with specifically designed geometries, the study indicates that the bath formulations critically control the electrogalvanizing characteristics and affect the coating surface morphology, deposition rate, throwing power, coating uniformity, and residual stresses developed during and after electrogalvanizing. The coatings produced from baths with a moderate Zn-to-NaOH ratio of 0.067–0.092 appear to provide uniform and compact deposits, moderately high deposition rate, and relatively low residual stresses.
Highlights
Owing to their relatively simple fabrication process and ten to hundred times higher corrosion resistance than ferrous materials depending on the environment, electrogalvanized zinc coatings have been widely employed to protect steels from corrosion in many industries ranging from automotive and machine elements to construction [1,2,3]
Several process parameters and variables such as chemical compositions of plating baths can potentially play a critical role in influencing the characteristics of electrogalvanized coatings, including the plating coverage, throwing power, and uniformity of coating thickness [10,11]
The understanding gained from this study provides fundamental knowledge for further development of the electroplated zinc coatings and benefits practical uses and controls of the electrogalvanized plating system
Summary
Owing to their relatively simple fabrication process and ten to hundred times higher corrosion resistance than ferrous materials depending on the environment, electrogalvanized zinc coatings have been widely employed to protect steels from corrosion in many industries ranging from automotive and machine elements to construction [1,2,3]. Fundamental studies aiming to understand the influencing factors of plating quality and to establish a process–property relationship of electrogalvanized coatings plated from the alkaline non-cyanide bath have been very limited. Several process parameters and variables such as chemical compositions of plating baths can potentially play a critical role in influencing the characteristics of electrogalvanized coatings, including the plating coverage, throwing power, and uniformity of coating thickness [10,11]. These factors could affect the development of internal stresses, which could subsequently result in the failure of deposited films, by mechanisms such as blistering or delamination. The understanding gained from this study provides fundamental knowledge for further development of the electroplated zinc coatings and benefits practical uses and controls of the electrogalvanized plating system
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