Electrodeposition Based Preparation of Zn–Ni Alloy and Zn–Ni–WC Nano-Composite Coatings for Corrosion-Resistant Applications

Channagiri Mohankumar Praveen Kumar,Avinash Lakshmikanthan,Khaled Giasin,Manjunath Patel Gowdru Chandrashekarappa,Danil Yurievich Pimenov

doi:10.3390/coatings11060712

Channagiri Mohankumar Praveen Kumar, Avinash Lakshmikanthan + Show 3 more

Open Access

https://doi.org/10.3390/coatings11060712

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Abstract

Zinc (Zn) is one of the five most widely consumed metals in the world. Indeed, more than 50% of all the zinc produced is used in zinc-galvanizing processes to protect steel from corrosion. Zn-based coatings have the potential for use as a corrosion-resistant barrier, but their wider use is restricted due to the poor mechanical properties of Zn that are needed to protect steel and other metals from rusting. The addition of other alloying elements such as Ni (Nickle) and WC (Tungsten Carbide) to Zn coating can improve its performance. This study investigates, the corrosion performance of Zn–Ni coating and Zn–Ni–WC composite nanocoatings fabricated on mild steel substrate in an environmentally friendly bath solution. The influence of WC nanoparticles on Zn–Ni deposition was also investigated. The surface morphologies, texture coefficients via XRD (X-ray diffraction), SEM (Scanning Electron Microscopy), and EDS (Energy-dispersive X-ray spectroscopy) were analyzed. The electrochemical test such as polarization curves (PC) and electrochemical impedance spectroscopy (EIS) resulted in a corrosion rate of 0.6948 Å/min for Zn–Ni–WC composite nanocoating, and 1.192 Å/min for Zn–Ni coating. The results showed that the Zn–Ni–WC composite nanocoating reduced the corrosion rate by 41.71% and showed an 8.56% increase in microhardness compared to the hardness of the Zn–Ni coating. These results are augmented to better wettable characteristics of zinc, which developed good interfacial metallurgical adhesion amongst the Ni and WC elements. The results of the novel Zn–Ni–WC nanocomposite coatings achieved a great improvement of mechanical property and corrosion protection to the steel substrate surface.

Highlights

IntroductionThe processing of different grades of steel alloys has a noticeable, commercial application due to their low cost and excellent mechanical and tribological properties [1]
The poor corrosion resistance of steel alloys limits their use in the construction industry [3], orthopedic implants [4], boat structures [5], manufacturing [6], and nuclear power plant [7] parts
The electrodeposition of the Zn–Ni alloy and the Zn–Ni–WC composites nanocoatings were applied on the substrate, i.e., mild steel possessing a geometry of 50 mm × 40 mm × 1 mm, from a sulphate bath

Summary

Introduction

The processing of different grades of steel alloys has a noticeable, commercial application due to their low cost and excellent mechanical and tribological properties [1]. Each steel grade often has its characteristics (phases, precipitates, properties) that are useful for certain applications [2]. The poor corrosion resistance of steel alloys limits their use in the construction industry [3], orthopedic implants [4], boat structures [5], manufacturing [6], and nuclear power plant [7] parts. Immediate attention is required to study the appropriate methods that can enhance the corrosion resistance of steel alloys and improve their service life

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Results

Conclusion