Pulse plating effect on microstructure and corrosion properties of Zn–Ni alloy coatings

The influence of pulse plating parameters on the surface morphology, grain size, lattice imperfection and corrosion properties of Zn–Ni alloy has been studied. The coatings were electrodeposited in an alkaline cyanide-free solution. AFM was applied for surface morphology examination, XRD measurements were carried out for phase composition and texture analysis, electron probe microanalysis was used for alloy chemical composition studies, while electrochemical techniques were applied for corrosion performance evaluation. The pulse plated Zn–Ni coatings appeared to consist of the γ-Zn₂₁Ni₅ phase and the composition of the alloy depended on the plating parameters. The grain size, lattice imperfection and homogeneity of grain distribution were established to be the main factors determining corrosion behaviour of the coating. Presented at the 4th Baltic Conference on Electrochemistry, Greifswald, March 13–16, 2005     

Electrochemical studies on Zn deposition and dissolution in sulphate electrolyte

The electrochemical deposition and dissolution of Zn on Pt electrode in sulphate electrolyte was investigated by electrochemical methods in an attempt to contribute to the better understanding of the more complex Zn–Cr alloy electrodeposition process. A decrease of the Zn electrolyte pH (from 5.4 to 1.0) so as to minimise/avoid the formation of hydroxo-products of Cr in the electrolyte for deposition of alloy coatings decreases the current efficiency for the Zn reaction, but the rate of the cathode reaction increases significantly due to intense hydrogen evolution. The results of the investigations in Zn electrolytes with pH 1.0–1.6 indicate that Zn bulk deposition is preceded by hydrogen evolution, stepwise Zn underpotential deposition (UPD) and formation of a Zn–Pt alloy. Hydrogen evolution from H₂O starts in the potential range of Zn bulk deposition. Data obtained from the electrochemical quartz crystal microbalance (EQCM) measurements support the assumption that electrochemical deposition of Zn proceeds at potentials more positive than the reversible potential of Zn. Anodic potentiodynamic curves for galvanostatically and potentiostatically deposited Zn layers provide indirect evidence about the dissolution of Zn from an alloy with the Pt substrate. The presumed potential of co-deposition of Cr (−1.9 V vs. Hg/Hg₂SO₄) is reached at a current density of about 300 mA cm⁻².     

Studies on electrodeposition of Zn–MoS<Subscript>2</Subscript> nanocomposite coatings on mild steel and its properties

Pure zinc and Zn–MoS₂ composite coatings were prepared by electrodeposition from zinc sulfate–chloride bath containing uniformly dispersed MoS₂ nanoparticles. The effect of MoS₂ on the deposition properties morphology, crystallographic orientation, and corrosion behavior were studied. The electrokinetic properties (zeta potential) and size distribution statistics in plating bath for the particles were evaluated using dynamic light scattering experiments. The Zn and Zn–MoS₂ deposition process was studied by linear polarization and cyclic voltammetry. Scanning electron microscopy, energy dispersive X-ray analysis, X-ray diffraction analysis, and potentiodynamic polarization measurements were used to characterize the coatings. The addition of MoS₂ to the electrolyte significantly changed the microstructure and crystallographic orientation of the zinc deposits and enhanced the corrosion resistance of the coatings. The morphological and electrochemical properties of the zinc coatings were observed to be significantly affected by the incorporation of MoS₂ particles into the zinc matrix.     

Surface analysis and corrosion resistance of new nickel base thin film alloys

Electroless Zn–Ni–P thin films were deposited on low carbon steel from an alkaline non‐cyanide aqueous electrolyte. The newly developed ternary alloys structure and microstructure investigations were carried out via X‐ray diffraction and SEM. Chemical composition of the coatings was investigated via energy dispersive spectroscopy. Polarization tests were used to study the corrosion properties of the coatings in a 3.5 wt.% NaCl solution. The results confirmed the high corrosion resistance of Zn–Ni–P alloy plated steel sheet. The surface analysis of the thin film samples before and after corrosion was performed by XPS. The incorporation of Zn in Ni–P thin film is proven for all initial samples to be as a mixture of zinc and zinc oxide, while nickel exists in +2 and +3 oxidized states. A passive film of a mixture of oxide and hydroxide of zinc and nickel forms on the surface and prevents the Zn–Ni–P thin films from corrosion. Copyright © 2014 John Wiley & Sons, Ltd.     

Ni-P-Zn_3(PO_4)_2(ZnSnO_3、ZnSiO_3)纳米复合化学镀层性质和组成的研究

研究了温度、时间、浓度等对 A3钢片上 Ni-P-Zn3(PO4)2、 Ni-P-ZnSnO3和 Ni-P-ZnSiO3纳米复合化学镀层外貌的影响。用扫描电子显微镜（ SEM）观察外貌;称重法测定厚度;通过 10％ NaCl溶液、 1％ H2S气体加速腐蚀试验、 10％ CuSO4溶液点滴试验等多种手段测定其耐腐蚀性能;用 X-射线光电子谱 (XPS)及俄歇电子能谱 (AES)测定其价态及组成。结果表明：在最佳施镀条件下,可得光亮、致密、耐腐蚀性强于 A3钢、磷化膜及 Ni-P镀层的纳米复合化学镀层。镀层的原子百分组成约为 (％ )： Ni-P-Zn3(PO4)2： Ni 70.00,P 12.47,Zn3(PO4)2 13.93,C 3.6; Ni-P-ZnSnO3： Ni 77.56,P 10.00,ZnSnO3 9.84,C 2.6; Ni-P-ZnSiO3： Ni 83.00,P 10.96,ZnSiO3 5.15,C 0.89。     

Electrodeposition behavior of Mg with Zn from acidic sulfate solutions

Electrodeposition of Mg with Zn in acidic sulfate solutions with polyethylene glycol and octadecyl dimethyl benzyl ammonium chloride as additives was investigated by scanning electron microscopy, X-ray diffraction, and potentiodynamic polarization techniques. The results show that these two compounds act in a synergetic way to suppress Zn deposition markedly and facilitate Mg reduction. Zn–0.46%Mg coatings are produced under high cathodic current densities, which have lower corrosion potentials than Zn coatings and hydrogen evolution in neutral chloride solutions. Magnesium hydroxide may cause current oscillations at high cathodic polarizations in plating solutions without zinc salts due to its formation and peel-off. An “induced co-deposition” mechanism is proposed for Zn–Mg alloy electrodeposition.     

Development of analytical procedures for the determination of hexavalent chromium in corrosion prevention coatings used in the automotive industry

The European directive 2000/53/EC limits the use of Cr(VI) in vehicle manufacturing. Although a maximum of 2 g of Cr(VI) was authorised per vehicle for corrosion prevention coatings of key components, since July 2007 its use has been prohibited except for some particular applications. Therefore, the objective of this work was to develop direct analytical procedures for Cr(VI) determination in the different steel coatings used for screws. Instead of working directly with screws, the optimisation of the procedures was carried out with metallic plates homogeneously coated to improve the data comparability. Extraction of Cr(VI) from the metallic parts was performed by sonication. Two extraction solutions were tested: a direct water extraction solution used in standard protocols and an ammonium/ammonia buffer solution at pH 8.9. The extracts were further analysed for Cr speciation by high-performance liquid chromatography (HPLC) inductively coupled plasma (ICP) atomic emission spectrometry or HPLC ICP mass spectrometry depending on the concentration level. When possible, the coatings were also directly analysed by solid speciation techniques (X-ray photoelectron spectroscopy, XPS, and X-ray absorption near-edge structure, XANES) for validation of the results. Very good results between the different analytical approaches were obtained for the sample of coating made up of a heated paint containing Zn, Al and Cr when using the extracting buffer solution at pH 8.9. After a repeated four-step extraction procedure on the same portion test, taking into account the depth of the surface layer reached, good agreement with XPS and XANES results was obtained. In contrast, for the coatings composed of an alkaline Zn layer where Cr(VI) and Cr(III) are deposited, only the extraction procedure using water allowed the detection of Cr(VI). To elucidate the Cr(VI) reduction during extraction at pH 8.9, the reactivity of Cr(VI) towards different species of Zn generally present in the coatings (metallic Zn and zinc oxide) was studied. The results showed that metallic Zn rapidly reduces Cr(VI), whereas this reaction is less evident in the presence of zinc oxide. Water was then retained for coatings containing metallic Zn.     

Effect of Cr(III) passivation layer on surface modifications of zinc-nickel coatings in chloride solutions

Surface chemical and morphological modifications of as-plated and Cr(III)-passivated monophasic zinc-nickel coatings induced by corrosion in chloride solutions are demonstrated. The passivated samples showed slower anodic dissolution, less significant de-alloying, smaller surface dezincification and lower coating cracking, as demonstrated by Scanning Electron Microscopy and Energy Dispersive X-ray Spectroscopy (SEM-EDX) of the surface and inductively coupled plasma atomic emission spectroscopy solution analysis. Surface characterization by X-ray photoelectron spectroscopy (XPS), Raman spectroscopy and SEM-EDS indicated simonkolleite as the main corrosion product for both, as-plated and Cr(III)-passivated coatings. In contrast, only for as-plated coating, which experienced higher cracking, new Ni containing phases (metallic Ni and NiO) were evidenced. The phase transition via selective dissolution of zinc is supposed to increase the concentration of the structural defects and could explain cracking in the non-passivated Zn-Ni coating.

     

Features of formation of magnetite coatings on low-carbon steel in hot nitrate solutions

The process of anticorrosion magnetite coating (MC) formation on low-carbon steel is studied in alkali-free nitrate converting media at the temperatures of 70–98°C reduced as compared to those used (130–145°C) in standard technologies of steel bluing: formation of such coatings in alkaline nitrate solutions. Alongside with the conventional corrosion-electrochemical methods of analysis of the formed MCs, the regularities of the MC surface reliefs were studied using the method of atomic force microscopy combined with the technique of flicker-noise spectroscopy (FNS) for processing digitized images and obtaining the parameters of the MC surface structure in different nanometer ranges. It was shown that it is necessary to introduce additives of metal nitrates with a low cation radius into the ammonium nitrate converting solution to obtain MCs with a high corrosion stability at the first stage of MC formation and the final stage must consist in the further “passivation” of MCs: MC treatment by aqueous solutions based on nontoxic carboxylates. According to the FNS analysis of the surface structure of the formed MCs, a significant decrease of the FNS “point” factor, an indicator of MC corrosion instability, occurred during the final treatment. On this basis, one could characterize quantitatively the results of accelerated corrosion tests: no steel corrosion occurred on the thus formed coatings for 42 days under standard severe conditions: 100% relative humidity and daily “showering”. The performed study reveals fundamental possibilities for solving the problems of standardization of the anticorrosion coating surface based on the analysis of their surface profile in the nanometer range.     

Improvement in corrosion resistance of micro arc oxidation coating formed on AZ91D magnesium alloy via applying a nano-crystalline sol–gel layer

Although magnesium is used in many industries, it is reactive and requires protection against aggressive environments. In this study, oxide coating was formed on AZ91D magnesium alloy using micro-arc oxidation (MAO) process in an alkaline electrolyte. Then, in order to seal the pores in the oxide film, a sol–gel layer was applied to the surface of the MAO coating by dipping. For investigation of heat treatment temperature of the sol–gel layer on the properties of the coatings, two different temperatures (150 and 350 °C) were chosen. Surface morphologies and compositions of the coatings were analyzed by Scanning Electron Microscope and X-ray Diffraction (XRD). Surface roughness of the coatings was also measured. The corrosion behavior of the coatings was evaluated with Electrochemical Impedance Spectroscopy and potentiodynamic polarization tests in 3.5 wt%NaCl solution. The porosity percent of the coatings was measured by potentiodynamic polarization tests results. It is found that the sol–gel layers successfully cover the pores of the MAO coatings. The results of the corrosion tests show that the sol–gel layers significantly increase the corrosion resistance of the substrate by reducing the percent of the porosity. The grain size measurements by XRD analysis shows that the grain size of the sol–gel layer heated in 350 °C is about 50 nm.     

Electrochemical deposition and corrosion stability of Zn–Co alloys

Electrochemically deposited Zn–Co alloys under various deposition conditions were investigated using anodic linear sweep voltammetry for phase structure determination, scanning electron microscopy for surface morphology analysis, atomic absorption spectroscopy for determination of chemical composition, and polarization measurements and open circuit potential measurements for determination of corrosion properties. The influence of deposition current density, temperature, and composition of deposition solution on the phase structure and corrosion properties of Zn–Co alloys was studied. It was shown that the ratio of cobalt to zinc ions in the plating bath strongly affects the chemical content and phase structure, as well as corrosion stability, of Zn–Co alloys. Zn–Co alloys deposited from plating baths with the lowest and the highest ratios of cobalt and zinc ions exhibited the lowest corrosion rate.     

Electrodeposition and characterization of zinc–nickel–iron alloy from sulfate bath: influence of plating bath temperature

The electrodeposition of ternary zinc–nickel–iron alloy was studied in acidic sulfate bath. The comparison between Zn, Ni, and Fe deposition and Zn–Ni and Zn–Ni–Fe co-deposition revealed that the remarkable inhibition of Ni and Fe deposition takes place due to the presence of Zn²⁺ in the plating bath. The increase in corrosion resistance of ternary deposits is not only attributed to the formation of γ-Ni₂Zn₁₁ phase but also to iron co-deposition and formation of iron phase. It was also found that the bath temperature has a great effect on the surface appearance and the deposit composition. The investigation was carried out using cyclic voltammetry and galvanostatic techniques for electrodeposition, while linear polarization resistance and anodic linear sweeping voltammetry techniques were used for corrosion study. Morphology and chemical composition of the deposits were characterized by means of scanning electron microscopy and atomic absorption spectroscopy.     

Enhancement of corrosion resistance of electrocodeposited Ni–SiC composites by magnetic field

The corrosion behavior and surface morphology of Ni–SiC composite coatings produced by electrodeposition with the aid of magnetic field were studied. The results of the electrochemical analysis including polarization resistance and potentiodynamic polarization curves showed that a magnetic field of 0.1 T could significantly improve the corrosion resistance of the composite. The electrochemical impedance spectra revealed that a passive layer was formed on the surface of the Ni–SiC coating with the magnetic field. The microstructures of electrodeposited Ni–SiC composite coatings were also examined. More SiC particles were found to be incorporated into the coating with the presence of magnetic field, which was considered to be one of the reasons for the enhancement of corrosion resistance as SiC particles were reported to be corrosion inhibitors. Contribution to special issue “Magnetic field effects in Electrochemistry”     

Electrochemical corrosion behaviors and corrosion protection properties of Ni–Co alloy coating prepared on sintered NdFeB permanent magnet

In this study, a protective Ni–Co alloy coating was prepared on sintered NdFeB magnet applying electrodeposition technique. A pure nickel coating was also studied for a comparison. The microstructure, surface morphologies, and chemical composition of coatings were investigated using X-ray diffraction, scanning electron microscope, and energy dispersive spectroscopy, respectively. The corrosion protection properties of coatings for NdFeB magnet in neutral 3.5 wt.% NaCl solutions were evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) techniques. The microstructure and surface morphologies analysis showed that the addition of cobalt element into matrix metal Ni altered the preferential orientation of pure nickel coating from (2 0 0) crystal face for pure nickel coating to (1 1 1) crystal face for Ni–Co alloy coating, and made the surface morphologies more compact and uniform due to the grain-refining. The results of potentiodynamic polarization test showed that compared with pure nickel coating, Ni–Co alloy coating exhibited much nobler corrosion potential (E _corr) and lower corrosion current density (j _corr), indicating better anticorrosive properties. The long-term immersion test by dint of EIS indicated that the Ni–Co alloy coating still presented high impedance value of 1.9 × 10⁵ Ω cm² with the immersion time of 576 h indicating the excellent anticorrosive properties, and corrosion protection properties of nickel coating for NdFeB magnet practically disappeared with the immersion time of 144 h, which also indicated that the Ni–Co alloy coating provided better corrosion protection properties for the NdFeB magnet compared with nickel coating.     

A zirconia-polyester glycol coating on differently pretreated AISI 316L stainless steel: corrosion behavior in chloride solution

The effect of zirconia and zirconia-polyester glycol hybrid coatings on the corrosion resistance of mechanically polished or anodized AISI 316 stainless steel (316L), was studied by potentiodynamic polarization and electrochemical impedance spectroscopy in 0.1 M NaCl and scanning electron microscope and atomic force microscopy examinations. The deposition of zirconia coatings was achieved by the sol–gel technique by immersing the samples in either the inorganic polymer or the organic–inorganic polymer mixture. From potentiodynamic and impedance measurements, the grade of protection is reduced with the exposure time to the electrolyte, which is mainly associated with lost of film adhesion and, consequently, detachment from the metal substrate. However, the uncoated anodized sample revealed an unexpected corrosion behavior; the anodic film formed during anodizing readily increased the corrosion resistance of the 316L stainless steel in 0.1 M NaCl, revealing a considerable reduction in the corrosion current density and an increase in the pitting potential.     

Electrodeposition of Zn–TiO<Subscript>2</Subscript> nanocomposite films—effect of bath composition

Zn–TiO₂ nanocomposite films were prepared by pulsed electrodeposition from acidic zinc sulphate solutions on a Ti support. The influence on the composite structural and morphological characteristics of Zn²⁺ and TiO₂ concentrations in the deposition bath has been investigated. The characterisation of the samples was made by X-ray diffraction and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM/EDS). For all the obtained coatings, the anatase and rutile phases’ most intense diffraction lines were observed between 24° and 28° 2θ, confirming the formation of the Zn–TiO₂ nanocomposite. X-ray diffraction data show that the presence of the TiO₂ nanoparticles plays a remarkable influence on the preferred orientation of the metal matrix. For the more diluted solution, a dependence between the metallic matrix grain size and the concentration of TiO₂ in bath is observed. The grain size decreases with the increasing on the nanoparticle amounts. The SEM results for Zn and Zn–TiO₂ deposits indicate that the nanoparticles have a strong influence on the deposit surface morphology, which is caused by the changes on the deposition mechanism.     

Surface Characterisation of Water-Atomised Al–Zn–Mg–Cu Alloy Powders by SIMS and AES

 The present paper focuses on the characterisation of surface composition and alloying element in-depth distribution of water-atomised Al–Zn–Mg–Cu alloy powders by secondary ion mass-spectrometry and Auger electron spectroscopy. A pronounced segregation of Mg and some impurities (Fe, Ca, S) concurrently with some Zn depletion are observed on the powder surface. The oxide film formed on the powder surface mainly consists of Al and Mg oxides. The film is non-uniform in thickness: rather coarse surface oxide islands coexist with surface areas covered by a thin (<1.8 nm) oxide layer. The extent of surface oxidation is strongly affected by solidification conditions: The average thickness of the surface oxides increases with increasing particle size or with decreasing cooling rate. All alloying elements are homogeneously distributed in the bulk of individual particles. No significant differences in chemical composition between different particles of a given powder are observed. Received November 26, 1999. Revision September 25, 2001.     

Growth behaviour of cerium-based conversion coating on Zn-5%Al alloy

Cerium-based conversion coatings were deposited on a Zn-5%Al alloy by immersing the alloy in cerium nitrate aqueous solutions with various immersion times. The growth behaviour of the cerium-based conversion coating on the Zn-5%Al alloy was investigated by the electrochemical impedance spectroscopy (EIS), SEM, energy dispersive spectroscopy (EDS), and XPS techniques. The results reveal that the coating mainly consists of ZnO, Zn(OH)₂, Ce(OH)₄, Ce(OH)₃, CeO₂, and Ce₂O₃. The growth of the cerium-based conversion coating is accompanied by metal dissolution. The dissolution mainly occurs on the η-Zn surface of the phase boundary and continues to extend to the Zn-rich phase as the coating grows. EIS results show that with increasing immersion time, the corrosion resistance of the Ce conversion coating gradually increases in the early growth stage and then decreases when the cracks appear.     

Inhibition effect of cerium in hybrid sol–gel films on aluminium alloy AA2024

Aluminium alloys such as AA2024 are susceptible to severe corrosion attack in aggressive solutions (e.g. chlorides). Conversion coatings, like chromate, or rare earth conversion coatings are usually applied in order to improve corrosion behaviour of aluminium alloys. Methacrylate‐based hybrid films deposited with sol–gel technique might be an alternative to conversion coatings. Barrier properties, paint adhesion and possibly self‐healing ability are important aspects for replacement of chromate‐based pre‐treatments. This work evaluates the behaviour of cerium as corrosion inhibitor in methacrylate silane‐based hybrid films containing SiO₂ nano‐particles on AA2024. Hybrid films were deposited on aluminium alloy AA2024 by means of dip‐coating technique. Two different types of coating were applied: a non‐inhibited film consisting of two layers (non‐inhibited system) and a similar film doped with cerium nitrate in an intermediate layer (inhibited system). The film thickness was 5 µm for the non‐inhibited system and 8 µm for the inhibited system. Film morphology and composition were investigated by means of GDOES (glow discharge optical emission spectroscopy). Moreover, GDOES qualitative composition profiles were recorded in order to investigate Ce content in the hybrid films as a function of immersion time in 0.05 M NaCl solution. The electrochemical behaviour of the hybrid films was studied in the same electrolyte by means of EIS technique (electrochemical impedance spectroscopy). Electrochemical measurements provide evidence that the inhibited system containing cerium displays recovery of electrochemical properties. This behaviour is not observed for the non‐inhibited coating. GDOES measurements provide evidence that the behaviour of inhibited system can be related to migration of Ce species to the substrate/coating interface. Copyright © 2010 John Wiley & Sons, Ltd.     

Effects of serum proteins on corrosion behavior of ISO 5832–9 alloy modified by titania coatings

Stainless steel ISO 5832–9 type is often used to perform implants which operate in protein-containing physiological environments. The interaction between proteins and surface of the implant may affect its corrosive properties. The aim of this work was to study the effect of selected serum proteins (albumin and γ-globulins) on the corrosion of ISO 5832–9 alloy (trade name M30NW) which surface was modified by titania coatings. These coatings were obtained by sol–gel method and heated at temperatures of 400 and 800 °C. To evaluate the effect of the proteins, the corrosion tests were performed with and without the addition of proteins with concentration of 1 g L^?1 to the physiological saline solution (0.9 % NaCl, pH 7.4) at 37 °C. The tests were carried out within 7 days. The following electrochemical methods were used: open circuit potential, linear polarization resistance, and electrochemical impedance spectroscopy. In addition, surface analysis by optical microscopy and X-ray photoelectron spectroscopy (XPS) method was done at the end of weekly corrosion tests. The results of corrosion tests showed that M30NW alloy both uncoated and modified with titania coatings exhibits a very good corrosion resistance during weekly exposition to corrosion medium. The best corrosion resistance in 0.9 % NaCl solution is shown by alloy samples modified by titania coating annealed at 400 °C. The serum proteins have no significant effect onto corrosion of investigated biomedical steel. The XPS results confirmed the presence of proteins on the alloy surface after 7 days of immersion in protein-containing solutions.