Skip to main content
SpringerLink
Log in

A Comparative Study of Pulse and DC Electroplating of Zn onto Mild Steel for Improved Corrosion Resistance

  • Original Article
  • Published:
Transactions of the Indian Institute of Metals Aims and scope Submit manuscript

Abstract

In the current study, Zn electrodeposition was done from an acidic sulfate bath onto mild steel at a pH of 3.5. The Zn coating was done in both direct current (DC) and the pulsed current mode to investigate whether the two techniques would lead to a difference in the corrosion behavior of the plated films. The range of deposition current density was obtained through a systematic cyclic voltammetry (CV). The chosen current density values were − 50, − 150, − 180, and − 250 mA/cm2. Pulse deposition was done after the DC deposition at the average current density of − 180 mA/cm2 at different duty cycles, frequencies and peak current densities. The thickness of the coating was measured by using a surface profilometer and was found to be in the range of 10–28 µm. Phase, structure and composition of the deposition were characterized by XRD, SEM and elemental mapping. Tafel polarization technique and electrochemical impedance spectroscopy were done to study the corrosion rate and mechanism in 3.5 wt% NaCl. A marginal increase in corrosion resistance was observed for pulse-deposited films as compared to DC-deposited ones. Films deposited at − 180 mA/cm2 and a combination of duty cycle, i.e., peak current density of − 720 mA/cm2 and at the frequency of 75 Hz, were found to have the optimum anti-corrosion performance.

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

Similar content being viewed by others

References

  1. Karthick S, Muralidharan S, and Saraswathy V, Arab J Chem 13 (2020) 3301. https://doi.org/10.1016/j.arabjc.2018.11.005

    Article  CAS  Google Scholar 

  2. Shibli S M A, Meena B N, and Remya R, Surf Coat Technol 262 (2015) 210. https://doi.org/10.1016/j.surfcoat.2014.12.054

    Article  CAS  Google Scholar 

  3. Asgari H, Toroghinejad M R, and Golozar M A, Curr Appl Phys 9 (2009) 59. https://doi.org/10.1016/j.cap.2007.10.090

    Article  Google Scholar 

  4. Verma A R B, and Van Ooij W J, Surf Coat Technol 89 (1997) 132. https://doi.org/10.1016/S0257-8972(96)02941-6

    Article  CAS  Google Scholar 

  5. Vasilakopoulos D, Bouroushian M, and Spyrellis N, Electrochim Acta 54 (2009) 2509. https://doi.org/10.1016/j.electacta.2008.11.059

    Article  CAS  Google Scholar 

  6. Bengoa L N, Bruno S, Lazzarino H A, Seré P R, and Egli W A, Mater Sci 8 (2015) 1174. https://doi.org/10.1016/j.mspro.2015.04.183

    Article  CAS  Google Scholar 

  7. Dattilo M, Cole E R, and O’Keefe T J, Conserv Recycl 9 (1986) 55. https://doi.org/10.1016/0361-3658(86)90134-7

    Article  CAS  Google Scholar 

  8. Feng Z, Li Q, Zhang J, Yang P, and An M, Surf Coat Technol 270 (2015) 47. https://doi.org/10.1016/j.surfcoat.2015.03.020

    Article  CAS  Google Scholar 

  9. Jyotheender K S, and Srivastava C, Metall Mater Trans A Phys Metall Mater Sci 52 (2021) 364. https://doi.org/10.1007/s11661-020-06070-y

    Article  CAS  Google Scholar 

  10. Rekha M Y, and Srivastava C, Corros Sci 152 (2019) 234. https://doi.org/10.1016/j.corsci.2019.03.015

    Article  CAS  Google Scholar 

  11. Sahayata B, Kumar S, Upadhyay P, Mendon R R, and Mallik A, Mater Lett 351 (2023) 135013. https://doi.org/10.1016/j.matlet.2023.135013

    Article  CAS  Google Scholar 

  12. Fathy N, Kobayashi R, and Ichimura M, Mater Sci Eng B Solid-State Mater Adv Technol 107 (2004) 271. https://doi.org/10.1016/j.mseb.2003.11.021

    Article  CAS  Google Scholar 

  13. Ataie S A, and Zakeri A, Surf Coat Technol 359 (2019) 206. https://doi.org/10.1016/j.surfcoat.2018.12.063

    Article  CAS  Google Scholar 

  14. Doğan F, Uysal M, Duru E, Akbulut H, and Aslan S, J Asian Ceram Soc 8 (2020) 1271. https://doi.org/10.1080/21870764.2020.1840704

    Article  Google Scholar 

  15. Ollendorf H, and Schneider D, Surf Coat Technol 113 (1999) 86. https://doi.org/10.1016/S0257-8972(98)00827-5

    Article  CAS  Google Scholar 

  16. Kabir M S, Munroe P, Zhou Z, and Xie Z, Wear 380–381 (2017) 163. https://doi.org/10.1016/j.wear.2017.03.020

    Article  CAS  Google Scholar 

  17. Sahu R K, Mukherjee D, Tiwari J P, Mishra T, and Pathak L C, J Mater Chem 19 (2009) 6810. https://doi.org/10.1039/b908080e

    Article  CAS  Google Scholar 

  18. Ju H, Wu J, and Xu Y, J Chem Sci 125 (2013) 687. https://doi.org/10.1007/s12039-013-0407-9

    Article  CAS  Google Scholar 

  19. Ayagou M D D, Tran T T M, Tribollet B, Kittel J, and Duret-Thual C, Electrochim Acta 282 (2018) 775. https://doi.org/10.1016/j.electacta.2018.06.052

    Article  CAS  Google Scholar 

Download references

Acknowledgements

The authors are thankful to Department of Metallurgical and Materials Engineering, National Institute of Technology Rourkela and Tata Steel Limited Jamshedpur for providing the equipment and financial facility.

Funding

The funding was supported by Tata Steel (Grant No: 3000132079/132).

Author information

Authors and Affiliations

  1. Electrometallurgy and Corrosion Laboratory, Department of Metallurgical and Materials Engineeri, National Institute of Technology Rourkela, Rourkela, 769008, India

    Pundrikaksha Upadhyay & Archana Mallik

  2. R&D, Tata Steel Ltd., Jamshedpur, 831001, India

    Anushri Nag & Atanu Banerjee

  3. Department of Metallurgical and Materials Engineering, National Institute of Technology Rourkela, Rourkela, 769008, India

    Anindya Basu

  4. AMC Laboratory, Department of Metallurgical and Materials Engineering, National Institute of Technology Raipur, Chhattisgarh, 492010, India

    Sanjeev Das

Authors
  1. Pundrikaksha Upadhyay
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Anushri Nag
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Atanu Banerjee
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Anindya Basu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Sanjeev Das
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Archana Mallik
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

PU contributed to conceptualization, methodology, analysis, writing and draft preparation; AN provided methodology; AB contributed to conceptualization; AB performed data curation, formal analysis, and review and editing; SD performed data curation and formal analysis; AM contributed to supervision, funding acquisition, conceptualization, data curation, formal analysis, and writing— review and editing.

Ethics declarations

Conflict of interest

The authors claim that they have no apparent financial conflicts of interest or close personal connections that could have appeared to have an influence on the research described in this work.

Additional information

Publisher's Note

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

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Upadhyay, P., Nag, A., Banerjee, A. et al. A Comparative Study of Pulse and DC Electroplating of Zn onto Mild Steel for Improved Corrosion Resistance. Trans Indian Inst Met 77, 1393–1405 (2024). https://doi.org/10.1007/s12666-023-03108-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12666-023-03108-8

Keywords

Search

Navigation