Skip to main content

Advertisement

SpringerLink
Log in

Development of Zn–ZrB2 nanocomposite coatings for wear, corrosion resistance and microstructure enhancement of carbon steel in saline environment

  • Original Paper
  • Published:
Chemical Papers Aims and scope Submit manuscript

A Correction to this article was published on 06 July 2022

This article has been updated

Abstract

Nanocomposite coatings are increasingly being used in marine industries to enhance the performance of carbon steel. However, while some of these coatings deteriorate rapidly with time when in continuous contact with contaminants in the saline environments, others are relatively stable. This work was therefore designed to examine the mechanical properties, corrosion resistance and microstructure characteristics of coatings on SAE-1020 carbon steel. After preliminary runs of the experiment, coated samples were developed containing ZrB2 nanoparticles of 7 and 13 g L−1, at cell voltages of 0.3 and 0.5 V, and at a constant temperature of 45 °C. The corrosion rate of the coated samples was investigated in 3.50 wt.% NaCl solution using potentiodynamic polarization technique in accordance with ASTM standard, while a pin-on-disc tribometer was used to determine the wear volume. The result of the potentiodynamic polarization test indicated that there was an enhancement in corrosion resistance. A reduction in corrosion rate from 9.7425 to 0.2439 mm year−1, highest coating efficiency of 97.5%, highest polarization resistance of 675.65 Ω and an extremely low current density of 2.10 × 10–5 A cm−2 were observed. These corrosion property values indicated significant protection of the carbon steel’s active sites. The wear volume was also observed to have reduced from 0.00508 mm−3 for the uncoated carbon steel to a minimum value of 0.00285 mm−3 for the 0.5Zn-13ZrB2 (at 0.5 V with 13 g/L ZrB2) coated steel, which was ascribed to the dispersion-strengthening and self-lubrication ability of the ZrB2 nanoparticles.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

Change history

References

  • Aghababaei R, Warner DH, Molinari JF (2017) On the debris-level origins of adhesive wear. Procee Nat Acad Sci 114:7935–7940

    Article  CAS  Google Scholar 

  • Akande IG, Oluwole OO, Fayomi OSI (2019) Optimizing the defensive characteristics of mild steel via the electrodeposition of Zn-Si3N4 reinforcing particles. Defen Technol 15:526–532

    Article  Google Scholar 

  • Akande IG, Fajobi MA, Odunlami OA, Oluwole OO (2021) Exploitation of composite materials as vibration isolator and damper in machine tools and other mechanical systems: A review. Mater Today Procee 43:1465–1470

    Article  Google Scholar 

  • Alipour K, Nasirpouri F (2019) Effect of morphology and surface modification of silica nanoparticles on the electrodeposition and corrosion behavior of zinc-based nanocomposite coatings. J Electrochem Soci 166:D1–D9

    Article  CAS  Google Scholar 

  • Asl MS, Nayebi B, Ahmadi Z, Zamharir MJ, Shokouhimehr M (2018) Effects of carbon additives on the properties of ZrB2–based composites: a review. Ceram Int 44:7334–7348

    Article  CAS  Google Scholar 

  • Bekmurzayeva A, Duncanson WJ, Azevedo HS, Kanayeva D (2018) Surface modification of stainless steel for biomedical applications: revisiting a century-old material. Mater Sci Eng C 93:1073–1089

    Article  CAS  Google Scholar 

  • Bhandari J, Khan F, Abbassi R, Garaniya V, Ojeda R (2015) Modelling of pitting corrosion in marine and offshore steel structures–A technical review. J Loss Preven Proc Ind 37:39–62

    Article  CAS  Google Scholar 

  • Cornide J, Dahlborg U, Leong Z, Dominguez LA, Juraszek J, Jouen S ... Calvo-Dahlborg M (2015) Structure and properties of some CoCrFeNi-Based high entropy alloys. TMS 144th Annual Meeting & Exhibition, 1147–1155

  • Dagdag O, El Harfi A, Safi Z, Guo L, Verma C, Ebenso EE, El Gouri M (2020) Fabrication on designing of a macromolecular epoxy resin as anti-corrosive coating material for electrocatalytically deposited cadmium on 15CDV6 steel in 3% NaCl solution. J Mater Resear Technol 9:5549–5563

    Article  CAS  Google Scholar 

  • Deepa K, Venkatesha TV (2019) Comparative anticorrosion performance of electrochemically produced Zn–NiO and Zn–NiO–ZrO2 composite coatings on mild steel. Surf Eng Appl Electrochem 55:317–323

    Article  Google Scholar 

  • Donatus U, Thompson GE, Liu Z (2015) Study of the effect of cadmium on the bimetallic corrosion behavior of AA2024T3 and mild steel couple. J Mater Eng Perf 24:1897–1905

    Article  CAS  Google Scholar 

  • Dubey S, Awasthi S, Nisar A, Balani K (2020) role of interfaces in damage initiation and tolerance of carbon nanotube-reinforced HfB2-ZrB2 ceramics. Jom 72:2207–2218

    Article  CAS  Google Scholar 

  • Fayomi OSI, Popoola API (2012) An investigation of the properties of Zn coated mild steel. Int J Electrochem Sci 7:6555–6570

    CAS  Google Scholar 

  • Gaugel S, Sripathy P, Haeger A, Meinhard D, Bernthaler T, Lissek F, Schneider G (2016) A comparative study on tool wear and laminate damage in drilling of carbon-fiber reinforced polymers (CFRP). Compos Struct 155:173–183

    Article  Google Scholar 

  • Gautam G, Mohan A (2015) Effect of ZrB2 particles on the microstructure and mechanical properties of hybrid (ZrB2+Al3Zr)/AA5052 insitu composites. J Alloys Comp 649:174–183

    Article  CAS  Google Scholar 

  • Hu C, Niu Y, Huang S, Li H, Ren M, Zeng Y, Sun J (2015) In-situ fabrication of ZrB2–SiC/SiC gradient coating on C/C composites. J Alloys Comp 646:916–923

    Article  CAS  Google Scholar 

  • Hu P, Gui K, Hong W, Zhang X, Dong S (2017) High-performance ZrB2-SiC-Cf composite prepared by low-temperature hot pressing using nanosized ZrB2 powder. J Europ Ceram Soci 37:2317–2324

    Article  CAS  Google Scholar 

  • Kainuma S, Yang M, Ishihara S, Kaneko A, Yamauchi T (2019) Corrosion protection of steel members using an Al-Zn base sacrificial anode and fiber sheet in an atmospheric environment. Const Building Mater 224:880–893

    Article  CAS  Google Scholar 

  • Katiyar PK, Singh PK, Singh R, Lava Kumar A (2016) Modes of failure of cemented tungsten carbide tool bits (WC/Co): A study of wear parts. Int J Refract Metal Hard Mater 54:27–38

    Article  CAS  Google Scholar 

  • Lee L, Behera P, Sriraman KR, Chromik RR (2018) The effect of contact stress on the sliding wear behaviour of Zn-Ni electrodeposited coatings. Wear 400:82–92

    Article  CAS  Google Scholar 

  • Liu Y, Fu Q, Wang B, Guan Y, Liu Y (2017) Ablation behavior of C/C-SiC-ZrB2 composites in simulated solid rocket motor plumes. J Alloys Comp 727:135–145

    Article  CAS  Google Scholar 

  • Lotfi N, Aliofkhazraei M, Rahmani H, Darband GB (2018) Zinc–nickel alloy electrodeposition: characterization, properties, multilayers and composites. Prot Met Phys Chem Surf 54:1102–1140

    Article  CAS  Google Scholar 

  • Loto CA, Akinyele M (2020) Effect of ginger, pomegranate and celery extracts on zinc electrodeposition, surface morphology and corrosion inhibition of mild steel. Alexan Eng J 59:933–941

    Article  Google Scholar 

  • Low CTJ, Wills RGA, Walsh FC (2006) Electrodeposition of composite coatings containing nanoparticles in a metal deposit. Surf Coat Technol 201:371–383

    Article  CAS  Google Scholar 

  • Maniam KK, Paul S (2021) Corrosion performance of electrodeposited zinc and zinc-alloy coatings in marine environment. Corros Mater Degrad 2:163–189

    Article  Google Scholar 

  • Mazumder S, Metselaar HSC, Sukiman NL, Zulkifli NWM (2021) Tribomechanical behaviour of non-oxide ceramic matrix composites in dry sliding. Tribolo Appli Compos Mater 1–49

  • Merlo AM (2003) The contribution of surface engineering to the product performance in the automotive industry. Surf Coat Technol 174:21–26

    Article  CAS  Google Scholar 

  • Montazeri M, Dehghanian C, Shokouhfar M, Baradaran A (2011) Investigation of the voltage and time effects on the formation of hydroxyapatite-containing titania prepared by plasma electrolytic oxidation on Ti–6Al–4V alloy and its corrosion behavior. Appl Surf Sci 257:7268–7275

    Article  CAS  Google Scholar 

  • Morales-Espejel GE, Gabelli A (2019) Rolling bearing seizure and sliding effects on fatigue life. Proc Inst Mech Eng, Part J J Eng Tribolo 233:339–354

    Article  Google Scholar 

  • Mruthunjaya M, Parashivamurthy KI (2014) Sliding wear behavior of Alumina/Tic coated steel produced by plasma spray technique. Bonfring Int J Ind Eng Man Sci 4:30–33

    Google Scholar 

  • Munagala VNV, Torgerson TB, Scharf TW, Chromik RR (2019) High temperature friction and wear behavior of cold-sprayed Ti6Al4V and Ti6Al4V-TiC composite coatings. Wear. https://doi.org/10.1016/j.wear.2018.11.032

    Article  Google Scholar 

  • Nagentrau M, Tobi AM, Sambu M, Jamian S (2019) The influence of welding condition on the microstructure of WC hardfacing coating on carbon steel substrate. Int J Refract Met Hard Mater 82:43–57

    Article  CAS  Google Scholar 

  • Nisar A, Khan MM, Balani K (2019) Enhanced thermo-mechanical damage tolerance of functionally graded ZrB2-20SiC ceramic reinforced with carbon nanotubes. Ceram Int 45:6198–6208

    Article  CAS  Google Scholar 

  • Oloruntoba DT, Popoola API (2015) Effect of coating on induced thermal and tensile stress on the fracture of exhaust pipe material. Eng Fail Analys 56:562–572

    Article  CAS  Google Scholar 

  • Orhorhoro EK, Erameh AA, Adingwupu AC (2018) Evaluation of the effect of tempering on the corrosion susceptibility of low carbon steel in sea water. Niger Resear J Eng Environ Sci 3:409–415

    Google Scholar 

  • Paul R, Dai L (2018) Interfacial aspects of carbon composites. Compos Interfaces 25:539–605

    Article  CAS  Google Scholar 

  • Rahman Rashid RA, Javed MA, Barr C, Palanisamy S, Matthews N, Dargusch MS (2021) Effect of in situ tempering on the mechanical, microstructural and corrosion properties of 316L stainless steel laser-cladded coating on mild steel. Int J Adv Man Technol 117:2949–2958

    Article  Google Scholar 

  • Reddy AP, Krishna PV, Rao RN (2017) Al/SiCNP and Al/SiCNP/X nanocomposites fabrication and properties: A review. J Nanomater Nanoeng Nanosyst 231:155–172

    CAS  Google Scholar 

  • Sayer M (2014) Elastic properties and buckling load evaluation of ceramic particles filled glass/epoxy composites. Compo Part B Eng 59:12–20

    Article  CAS  Google Scholar 

  • Sciti D, Zoli L, Vinci A, Silvestroni L, Mungiguerra S, Galizia P (2021) Effect of PAN-based and pitch-based carbon fibres on microstructure and properties of continuous Cf/ZrB2-SiC UHTCMCs. J Europ Ceram Soci 41:3045–3050

    Article  CAS  Google Scholar 

  • Selvam JDR, Dinaharan I (2017) In situ formation of ZrB2 particulates and their influence on microstructure and tensile behavior of AA7075 aluminum matrix composites. Eng Sci Technol, Int J 20:187–196

    Google Scholar 

  • Sgambetterra M, Zucca G, Di Francesco V, De Paolis F, Bernabei M (2020) Failure of Jet Engine Fuel Control Unit Originated by Corrosion of Cadmium Coating. J Fail Analys Preven 20:1470–1478

    Article  Google Scholar 

  • Shet VB, Bhat RS, Selvaraj R, Prasad G, Kodgi A, Damodaran A, Savithri A (2021) Development and optimization of Zn–Ni–TiO2 composite coating, assessment of its corrosion resistance and antimicrobial activity. Appl Nanosci 11:2469–2477

    Article  CAS  Google Scholar 

  • Siddiq SA, Sivakumar ER, Rao KK, Amburi PK, Sreenivasan M (2021) Comprehensive study of wear characteristics of alumina and Titanium Nitride ceramics against AISI 5140 steel under dry lubricated conditions. Des Eng 8:12700–12710

    Google Scholar 

  • Singh M, Asthana R (2007) Joining of zirconium diboride-based ultra high-temperature ceramic composites using metallic glass interlayers. Mater Sci Eng A 460:153–162

    Article  CAS  Google Scholar 

  • Sitler SJ, Charit I, Raja KS (2017) Room Temperature corrosion behavior of zrb2-hfb2 solid solutions in acidic and basic aqueous environments. Electrochim Acta 246:173–189

    Article  CAS  Google Scholar 

  • Sonber JK, Murthy TC, Sairam K, Nagaraj A, Majumdar S, Kain V (2018a) ZrB2 based novel composite with NiAl as reinforcement phase. Int J Refract Met Hard Mater 70:56–65

    Article  CAS  Google Scholar 

  • Sonber JK, Raju K, Murthy TC, Sairam K, Nagaraj A, Majumdar S, Kain V (2018b) Friction and wear properties of zirconium diboride in sliding against WC ball. Int J Refract Met Hard Mater 76:41–48

    Article  CAS  Google Scholar 

  • Su Y, Wang K, Gao J, Yang Y, Qin YX, Zheng Y, Zhu D (2019) Enhanced cytocompatibility and antibacterial property of zinc phosphate coating on biodegradable zinc materials. Acta Biomater 98:174–185

    Article  CAS  PubMed  PubMed Central  Google Scholar 

  • Suthar J, Patel KM (2018) Processing issues, machining, and applications of aluminum metal matrix composites. Mater Man Proc 33:499–527

    Article  CAS  Google Scholar 

  • Tang X, Wang H, Liu C, Zhu X, Gao W, Yin H (2021) Direct growth of hexagonal boron nitride nanofilms on stainless steel for corrosion protection. ACS Appl Nano Mater 4:12024–12033

    Article  CAS  Google Scholar 

  • Tisza M, Czinege I (2018) Comparative study of the application of steels and aluminium in lightweight production of automotive parts. Int J Lightweight Mater Man 1:229–238

    Google Scholar 

  • Vafa NP, Kakroudi MG, Asl MS (2020) Role of h-BN content on microstructure and mechanical properties of hot-pressed ZrB2–SiC composites. Ceram Int 46:21533–21541

    Article  CAS  Google Scholar 

  • Wang H, Liu Z, Zou L, Yang J (2017) Influence of both friction and wear on the vibration of marine water lubricated rubber bearing. Wear 376:920–930

    Article  CAS  Google Scholar 

  • Wang X, Shao X, Dai T, Xu F, Zhou JG, Qu G, Liu Y (2019) In vivo study of the efficacy, biosafety, and degradation of a zinc alloy osteosynthesis system. Acta Biomater 92:351–361

    Article  PubMed  CAS  Google Scholar 

  • Wang Y, Chen Y, Liu W, Ni X, Qing P, Zhao Q, Chen L (2021) Uniform and dendrite-free zinc deposition enabled by in situ formed AgZn3 for the zinc metal anode. J Mater Chem A 9:8452–8461

    Article  CAS  Google Scholar 

  • Wu L, Guo X, Zhang J (2014) Abrasive resistant coatings—a review. Lubricants 2:66–89

    Article  Google Scholar 

  • Xie Y, Cheng H, Tang Q, Chen W, Chen W, Dai P (2018) Effects of N addition on microstructure and mechanical properties of CoCrFeNiMn high entropy alloy produced by mechanical alloying and vacuum hot pressing sintering. Intermetallics 93:228–234

    Article  CAS  Google Scholar 

  • Yang M, Yuan J, Men X, Zhang Z, Guo F, Liu W (2016) Effect of ZrB2 particles incorporation on high-temperature tribological properties of hybrid PTFE/Nomex fabric/phenolic composite. Tribolo Int 99:289–295

    Article  CAS  Google Scholar 

  • Yuan W, Xia D, Wu S, Zheng Y, Guan Z, Rau JV (2022) A review on current research status of the surface modification of Zn-based biodegradable metals. Bioact Mater 7:192–216

    Article  CAS  PubMed  Google Scholar 

  • Zhang Z, Kovacevic R (2019) Laser cladding of iron-based erosion resistant metal matrix composites. J Man Proc 38:63–75

    Article  Google Scholar 

  • Zhang B, Zhang L, Xu J (2016a) Degradation feature selection for remaining useful life prediction of rolling element bearings. Qual Reliab Eng Int 32:547–554

    Article  Google Scholar 

  • Zhang SD, Wu J, Qi WB, Wang JQ (2016b) Effect of porosity defects on the long-term corrosion behaviour of Fe-based amorphous alloy coated mild steel. Corros Sci 110:57–70

    Article  CAS  Google Scholar 

  • Zhang Z, Sha J, Zu Y, Dai J, Liu Y (2019) Fabrication and mechanical properties of self-toughening ZrB2–SiC composites from in-situ reaction. J Adv Ceram 8:527–536

    Article  CAS  Google Scholar 

  • Zhang Y, Lunghi A, Sanvito S (2020) Pushing the limits of atomistic simulations towards ultra-high temperature: a machine-learning force field for ZrB2. Acta Mater 186:467–474

    Article  CAS  Google Scholar 

  • Zhao W, Zou Y, Matsuda K, Zou Z (2016) Characterization of the effect of hydrogen sulfide on the corrosion of X80 pipeline steel in saline solution. Corros Sci 102:455–468

    Article  CAS  Google Scholar 

Download references

Acknowledgements

This is to acknowledge Department of Mechanical Engineering, University of Ibadan for this research opportunity. Surface Engineering Research Centre, Ota, Nigeria is deeply appreciated for the provision of laboratory facilities.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Bells University of Technology, P.M.B. 1015, Ota, Ogun State, Nigeria

    Itopa Godwin Akande & Ojo Sunday Isaac Fayomi

  2. Department of Mechanical Engineering, University of Ibadan, Ibadan, Oyo State, Nigeria

    Itopa Godwin Akande, Oluleke Olugbemiga Oluwole & Olusegun Olufemi Ajide

Authors
  1. Itopa Godwin Akande
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ojo Sunday Isaac Fayomi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Oluleke Olugbemiga Oluwole
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Olusegun Olufemi Ajide
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Itopa Godwin Akande.

Ethics declarations

Conflict of interest

On behalf of all authors, the corresponding author states that there is no conflict of interest as regards this research work.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

The original Online version of this article was revised :The Optical micrograph section and the reference 2 have been incorrectly published.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Akande, I.G., Fayomi, O.S.I., Oluwole, O.O. et al. Development of Zn–ZrB2 nanocomposite coatings for wear, corrosion resistance and microstructure enhancement of carbon steel in saline environment. Chem. Pap. 76, 5839–5852 (2022). https://doi.org/10.1007/s11696-022-02270-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11696-022-02270-5

Keywords

Search

Navigation