Tribo-corrosion behavior of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coated mild steel

In this investigation , Zn-Ni-Cu and Zn-Ni-Cu-TiB₂ were coated on a mild steel specimen using a high velocity oxy fuel thermal spray (HVOF) process. The surface morphology and coated powder distribution of coated specimens were characterized using scanning electron microscope (SEM), energy dispersive spectroscopy (EDS), and X-ray-Elemental mapping. The pin-on-disc (ASTM G99-17) method was used to examine the wear resistance of the coated and uncoated mild steel specimens. Both coated Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on mild steel saw reduced wear volume loss than uncoated mild steel. The coated samples of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on Mild Steel were put through a scratch test to determine the adhesion strength of the coating with the substrate. The adhesion strength of coated Zn-Ni-Cu and Zn-Ni-Cu TiB2 mild steel was higher than that of untreated mild steel, indicating a solid link between the coating and substrate and minimal delamination. Using the Vickers hardness test to measure the hardness caused by the coating, it was shown that coated samples of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coated mild steel had significantly higher hardness than uncoated mild steel. Using ASTM G1-03 and ASTM G-31 standards, a 0.2 M HCl immersion cycle test was conducted for 28 days to test the corrosion resistance of coatings in an acidic media (672Hrs). When compared to Zn-Ni-Cu and Zn-Ni-Cu-TiB2 coated mild steel, the weight loss for the uncoated mild steel was significantly larger. Additionally, XRD examination showed that coated samples had less rust on their surface than uncoated samples. Both Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on Mild Steel were anti-corrosive, as evidenced by increased corrosion potential and reduced corrosion current density when compared to uncoated mild steel, according to electrochemical impedance spectroscopy (EIS)/Tafel study in 0.2 MHCl. The outcomes of each test were very encouraging and demonstrated the durability of these coatings against wear and corrosion.