Microstructure and Corrosion Resistance of Zn-Based Coatings: a Comparative Study

IF 0.9 Q3 Engineering

Surface Engineering and Applied Electrochemistry Pub Date : 2025-03-04 DOI:10.3103/S1068375524700595

Zhengjie Xing, Wangping Wu, Sheng Lin, Qinqin Wang, Yi Zhang

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Abstract

Corrosion in steel leads to significant resource waste. With that in view, three kinds of anti-corrosive Zn-based coatings were prepared on carbon steel, including electrodeposited Zn and Zn–Ni coatings, and as-sprayed Zn + Al coating. The microstructure, morphology, chemical composition, phase structure, and microhardness of the coatings were investigated using scanning electron microscopy, energy-dispersive spectroscopy, X-ray diffraction, and a Vickers microhardness tester. The wettability of the coatings was determined using a contact angle tester. The corrosion resistance of the coatings was evaluated through electrochemical impedance and dynamic polarization. The results revealed that Zn coatings consisted of the Zn phase with a hexagonal close-packed crystal structure. Zn–Ni coatings were composed of the Zn and Ni₅Zn₂₁ alloy phases. The as-sprayed Zn + Al coatings consisted of the Zn phase and the Al phase. The grain size of Zn coatings was 78.4 nm, and the grains were relatively large and irregular in shape. Zn–Ni coatings had a small grain size of 54.96 nm and exhibited some pinholes on the surface. Zn + Al coatings showed a flake-like structure with some micropores. The average microhardness values of Zn, Zn–Ni, and Zn + Al coatings were 112.6 ± 8.2 HV_0.5, 249.7 ± 9.8 HV_0.5, and 140.9 ± 7.6 HV_0.5, respectively. Zn and Zn + Al coatings exhibited hydrophilicity, while Zn–Ni coatings demonstrated hydrophobicity, which can effectively slow down the penetration of corrosive media. Zn–Ni coatings exhibited the best corrosion resistance, followed by Zn + Al coatings, while Zn coatings exhibited the poorest corrosion resistance.

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锌基涂层的微观结构与耐蚀性的比较研究

钢的腐蚀导致了严重的资源浪费。为此，在碳钢表面制备了3种锌基防腐涂层，分别为电沉积Zn、Zn- ni涂层和喷涂Zn + Al涂层。采用扫描电子显微镜、能量色散光谱、x射线衍射和维氏显微硬度计对涂层的显微组织、形貌、化学成分、相结构和显微硬度进行了研究。用接触角测试仪测定涂层的润湿性。通过电化学阻抗和动态极化对涂层的耐蚀性进行了评价。结果表明，镀层由具有六方密排晶体结构的Zn相组成。Zn - ni涂层由Zn相和Ni5Zn21合金相组成。喷涂后的Zn + Al涂层由Zn相和Al相组成。镀层晶粒尺寸为78.4 nm，晶粒较大，形状不规则。Zn-Ni涂层的晶粒尺寸较小，为54.96 nm，表面有针孔。Zn + Al涂层呈片状结构，并带有微孔。Zn、Zn - ni和Zn + Al镀层的显微硬度平均值分别为112.6±8.2 HV0.5、249.7±9.8 HV0.5和140.9±7.6 HV0.5。Zn和Zn + Al涂层具有亲水性，而Zn - ni涂层具有疏水性，可以有效减缓腐蚀介质的渗透。Zn - ni涂层的耐蚀性最好，Zn + Al涂层次之，Zn涂层的耐蚀性最差。

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来源期刊

Surface Engineering and Applied Electrochemistry Engineering-Industrial and Manufacturing Engineering

CiteScore

1.60

自引率

22.20%

发文量

期刊介绍： Surface Engineering and Applied Electrochemistry is a journal that publishes original and review articles on theory and applications of electroerosion and electrochemical methods for the treatment of materials; physical and chemical methods for the preparation of macro-, micro-, and nanomaterials and their properties; electrical processes in engineering, chemistry, and methods for the processing of biological products and food; and application electromagnetic fields in biological systems.