Protection of steel by sacrificial coatings is of primary importance in the industry, to extend the lifetime of steel structure parts. This is frequently obtained by zinc coatings, after galvanization or electrodeposition, but pure zinc is sometimes not resistant enough when high protective properties are required. Indeed, zinc corrosion rate is quite important, even if corrosion products play an important role in protection. Therefore, Zn alloys deposition is a privileged process. However, the metallic alloy elements used for codeposition are frequently composed of harmful substances, which use is more and more regulated. In a global strategy of employees and environment protection, and to anticipate more drastic restriction, the European plating shop leader Electropoli proposed a partnership to the research institute UTINAM. The project Zincadher intended to propose an alternative to zinc alloys plating by a zinc matrix, reinforced by silica and PMMA particles which main function is to increase corrosion resistance and adhesion. To overcome the lack of availability of PMMA (poly (methyl methacrylate)) nanoparticles at a reasonable price, an original synthesis of the PMMA particles was first developed [1]. It involves the use of a custom-made ultrasonic system, were MMA (methyl methacrylate) and water mixtures are exposed to different ultrasonic systems and successive sonication steps as follows: 20 kHz → 580 kHz → 858 kHz → 1138 kHz. Then, polymerization of the droplets is conducted, in order to obtain the largest possible concentration of PMMA particles of sub micrometer size range of different electrokinetic properties [2]. In a second part of the study, electrochemical study of acid zinc electrolyte with PMMA and/or silica particle have been carried out. As ultrasound is known to improve greatly mass transfer and coating characteristics as well as particles dispersion [3], a calibration of acoustic streaming at the surface of the working electrode is conducted, to be able to compare with classical mechanical stirring with the concept of equivalent velocity. Then, after particles dispersion in an acid zinc bath, composite coatings are elaborated. The plating parameters (current density, particles nature, hydrodynamic source…) on the morphology and composition of the coatings are evaluated by SEM/EDS and XRD characterization. Acknowledgement: The authors would like to thank Electropoli Group for funding this project and the ANRT for the CIFRE convention. [1] K. Nakabayashi, T. Fuchigami, M. Atobe, Electrochimica Acta. 110 593–598 (2013) [2] L Baissac, CC Buron, L Hallez, P Berçot, JY Hihn, L Chantegrel, G Gosse Ultrasonics sonochemistry 40, 183-192 (2018) [3] JY Hihn, F Touyeras, ML Doche, C Costa, BG Pollet in Power Ultrasound in Electrochemistry: From Versatile Laboratory Tool to Engineering Solution, John Wiley & Sons, Ltd, 169-214 (2012) Figure 1
Read full abstract