Ultrasonic-assisted supercritical-CO2 electrodeposition of Zn-Co film for high-performance corrosion inhibition: A greener approach

The ultrasonic-assisted electrodeposition process significantly improves the mechanical and electrochemical properties. Meanwhile, supercritical fluid technology also enhances the electrodeposition process with increased benefits, such as low surface tension, permeability, high diffusivity, and density, which improves the surface quality through grain refinement. In this study, Zn-Co films were prepared using the ultrasonic-assisted supercritical-CO₂ (US-SC-CO₂) electrodeposition approach, and its pressure effect on the film was evaluated. The films were also prepared by the conventional and typical supercritical-CO₂ (SC-CO₂) methods for a comparison study. All the prepared films were characterized by morphological studies, elemental composition, crystal structure orientation, and microhardness tests. Later, the fabricated films were examined by potentiodynamic polarization technique and electrochemical impedance technique (EIS) with 3.5 wt.% NaCl solution for corrosion evaluation. Based on results, Zn-Co film prepared through the US-SC-CO₂ process shows a spherical nodule like structure with reduced grain size and significantly enhanced hardness property. In XRD studies, the shift in diffracted peak’s position reveals the increased proportion of Co ions. Further, EDX results also confirm the same with the characteristic peaks. Finally, compared to the other methods, the corrosion resistance was more efficient in the US-SC-CO₂ process by 73.75%.