Abstract
Abstract Mild steel panels were zinc phosphated employing environmentally safe nano silica as an accelerator and a series of four cationic surfactants as additives. The four cationic surfactants chosen were decyltriethyl ammonium bromide (C10TEAB), dodecyltriethyl ammonium bromide (C12TEAB), hexadecyltriethyl ammonium bromide (C16TEAB), and octadecyltriethyl ammonium bromide (C18TEAB). The length of the alkyl chain of the surfactant compounds influenced the quality of the coatings. The corrosion resistance of the coated panels was assessed using a salt spray test. The hydrophobicity of the coatings increased as the hydrocarbon chain length of the surfactants extended from C10 to C18. Porosity, adhesion, and roughness tests were used to examine the surface properties of the coated panels. The coating weight and thickness of the resultant coatings on the base metal were used to quantify coating quality. The results of the tests revealed that the presence of C16TEAB additive outperformed all other components in terms of coating efficiency, coating thickness, and corrosion inhibition performance. The optimal quantity of C18TEAB deposited had a maximum coating weight of 0.0430 g/mm2 that enhanced durability, appearance, and barrier qualities.
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