Abstract
The influence of phosphate bath chemistry on phosphate coating properties and, eventually, on corrosion resistance properties of electrophoretic (ED) painted steel samples was examined. Two types of zinc phosphate bath chemistry with different concentration of zinc and nickel ions, and different values of total acid, free acid, and accelerator content were studied. The phosphate bath with higher value of acid ratio (total acid/free acid), nickel ion concentration, and accelerator point produced the best phosphate coating on steel surface with globular microstructure, small crystal size, high P ratio, and uniform coverage. Phosphate coated and only alkali cleaned samples were cathodic ED painted. Their corrosion resistance properties were evaluated by salt spray test, cyclic corrosion test and electrochemical impedance spectroscopy. The relative increase in corrosion resistance of painted sample due to best phosphate coating was 1·4 to 1·8×. Paint adhesion of samples significantly deteriorated when painted without phosphate pretreatment.
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