Electrodeposition Based Preparation of Zn–Ni Alloy and Zn–Ni–WC Nano-Composite Coatings for Corrosion-Resistant Applications

Abstract

Zinc (Zn) is one of the five most widely consumed metals in the world. Indeed, more than 50% of all the zinc produced is used in zinc-galvanizing processes to protect steel from corrosion. Zn-based coatings have the potential for use as a corrosion-resistant barrier, but their wider use is restricted due to the poor mechanical properties of Zn that are needed to protect steel and other metals from rusting. The addition of other alloying elements such as Ni (Nickle) and WC (Tungsten Carbide) to Zn coating can improve its performance. This study investigates, the corrosion performance of Zn–Ni coating and Zn–Ni–WC composite nanocoatings fabricated on mild steel substrate in an environmentally friendly bath solution. The influence of WC nanoparticles on Zn–Ni deposition was also investigated. The surface morphologies, texture coefficients via XRD (X-ray diffraction), SEM (Scanning Electron Microscopy), and EDS (Energy-dispersive X-ray spectroscopy) were analyzed. The electrochemical test such as polarization curves (PC) and electrochemical impedance spectroscopy (EIS) resulted in a corrosion rate of 0.6948 Å/min for Zn–Ni–WC composite nanocoating, and 1.192 Å/min for Zn–Ni coating. The results showed that the Zn–Ni–WC composite nanocoating reduced the corrosion rate by 41.71% and showed an 8.56% increase in microhardness compared to the hardness of the Zn–Ni coating. These results are augmented to better wettable characteristics of zinc, which developed good interfacial metallurgical adhesion amongst the Ni and WC elements. The results of the novel Zn–Ni–WC nanocomposite coatings achieved a great improvement of mechanical property and corrosion protection to the steel substrate surface.

Improvements of Arboblend V2 Nature Characteristics through Depositing Thin Ceramic Layers

“…Nickel, zirconium, aluminium, molybdenum and chromium, as powder elements, are a good choice for applications that require high toughness with moderate resistance to fretting, erosion and scuffing. Zinc-based coatings are widespread in applications that require increased corrosion resistance, but if this chemical element is not alloyed with other elements such as tungsten carbide or nickel, it has low mechanical characteristics [8]. The degradation of the Zn-polymer interface has been studied by the authors of the paper [9], and they point out that the delamination can be inhibited by CO 2 gas in a humid environment.…”

Nanomaterials in the Automobile Sector

“…The experimental results show that the flame retardant nanocoating can be used as a fire-warning sensor. There are varieties of nanocoatings prepared from metal, ceramic, and PNCs capable of protecting the metal surfaces from corrosion [65][66][67][68].…”

Effects of Chromium Carbide Coatings on Microstructure and Thermal Conductivity of Mg/Diamond Composites Prepared by Squeeze Casting

“…In order to improve the thermal conductivity, diamond surface coating [9][10][11] and metal matrix alloying [12][13][14] have been applied to enhance the interfacial bonding between the diamond and the metal matrix. The surface coating method excels in improving composite performance; Kumar et al developed a series of zinc-based coatings such as Zn-WO 3 [15] and Zn-Ni-WC composite nanocoatings [16], which exhibit excellent corrosion resistance and high hardness, greatly expanding the application of steel in boat structures, manufacturing, nuclear power plants, etc. Studies have shown that the addition of alloying elements can drastically reduce the TC of the magnesium matrix [17].…”