Abstract
Zinc is an important coating material for corrosion protection of carbon steel because of its sacrificial behavior. Continuous efforts have therefore been made over the years to perform required microstructural engineering to further enhance the corrosion resistance behavior of Zn based coatings. This review is focused on a new class of recently developed coatings in which carbonaceous materials like graphene, graphene oxide and carbon nanotubes (CNTs) are incorporated into Zn metal matrix to significantly affects its electrochemical response. Impermeability of the graphene and graphene oxide and hydrophobicity of the CNTs are the principal reasons behind the adoption of these carbonaceous additives. Over the years, the researchers have, however, observed that the in addition to the above, noticeable microstructural and morphological alterations introduced in the coating matrix due to these carbonaceous additives also contribute significantly to the corrosion resistance behavior. An understanding of the microstructural evolution of the coatings as a function of the additive volume fraction is therefore required to design robust composite coatings with enhanced corrosion resistance performance.
Funding source: CSIR India
Award Identifier / Grant number: CSIR
Funding source: Science and Engineering Research Board
Award Identifier / Grant number: SERB
About the authors
M. K. Punith Kumar received his MSc and PhD (2013) in chemistry. He was a postdoctoral fellow at University of Colorado Boulder and currently is working as a research associate in Indian Institute of Science. His research work includes the development of metal matrix composite coatings for corrosion protection applications as well as electrochemical sensor applications of graphene nano composites.
M. Y. Rekha received her PhD (2020) in materials engineering from Indian Institute of Science, Bengaluru, India. Currently she is working as a post-doctoral fellow at University of Alabama, Tuscaloosa, AL, USA. Her research work includes electrodeposition of coatings, corrosion, microstructural characterization of materials, and microstructure-property correlations.
Chandan Srivastava received his PhD (2009) in materials science from the University of Alabama, Tuscaloosa, AL, USA. He is currently working as an associate professor in the Department of Materials Engineering, Indian Institute of Science, Bengaluru, India. His research work includes microstructure and corrosion property correlation in composite coatings, synthesis, characterization and application of multi-component nanoparticles and coatings, synthesis, characterization and functional properties of metal cluster decorated graphene, size dependent phase stability in isolated nano-sized particles and nano-structured materials and application of electron microscopy technique for materials characterization.
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
Research funding: The authors would like to acknowledge the research funding received form the SERB and CSIR Government of India.
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
References
Aliyu, A. and Srivastava, C. (2019). Microstructure and corrosion properties of MnCrFeCoNi high entropy alloy-graphene oxide composite coatings. Materialia 5: 100249, https://doi.org/10.1016/j.mtla.2019.100249.Search in Google Scholar
Arora, S., Rekha, M.Y., Gupta, A., and Srivastava, C. (2018). High corrosion resistance offered by multi-walled carbon nanotubes directly grown over mild steel substrate. JOM 70: 2590–2595, https://doi.org/10.1007/s11837-018-2768-5.Search in Google Scholar
Arora, S., Kumari, N., and Srivastava, C. (2019). Microstructure and corrosion behaviour of NiCo-carbon nanotube composite coatings. J. Alloys Compd. 801: 449–459, https://doi.org/10.1016/j.jallcom.2019.06.083.Search in Google Scholar
Asl, S.M., Afshar, A., and Yaghoubinezhad, Y. (2018). An electrochemical synthesis of reduced graphene oxide/zinc nanocomposite coating through pulse-potential electrodeposition technique and the consequent corrosion resistance. Int. J. Corrosion 2018: 1–13.Search in Google Scholar
Bolelli, G., Giovanardi, R., Lusvarghi, L., and Manfredini, T. (2006). Corrosion resistance of HVOF-sprayed coatings for hard chrome replacement. Corrosion Sci. 48: 3375–3397, https://doi.org/10.1016/j.corsci.2006.03.001.Search in Google Scholar
Boshkov, N., Boshkova, N., Bachvarov, V., Peshova, M., and Lutov, L. (2015). Corrosion investigations of black chromite films on Zn and Zn-Co coatings with low cobalt content. J. Mater. Eng. Perform. 24: 4736–4745, https://doi.org/10.1007/s11665-015-1794-5.Search in Google Scholar
Chandran, M., Sarma, R.L., and Krishnan, R.M. (2003). Characteristics of non-cyanide acid zinc plating baths and coatings. Trans. Inst. Met. Fin. 81: 207–209, https://doi.org/10.1080/00202967.2003.11871541.Search in Google Scholar
Chen, D., Feng, H., and Li, J. (2012). Graphene oxide: preparation, functionalization, and electrochemical applications. Chem. Rev. 112: 6027–6053, https://doi.org/10.1021/cr300115g.Search in Google Scholar PubMed
Cheng, L., Liu, C., Han, D., Ma, S., Guo, W., Cai, H., and Wang, X. (2019). Effect of graphene on corrosion resistance of waterborne inorganic zinc-rich coatings. J. Alloys Compd. 774: 255–264, https://doi.org/10.1016/j.jallcom.2018.09.315.Search in Google Scholar
Chung, P.P., Wang, J., and Durandet, Y. (2019). Deposition processes and properties of coatings on steel fasteners – a review. Friction 7: 389–416, https://doi.org/10.1007/s40544-019-0304-4.Search in Google Scholar
Ge, T., Zhao, W., Wu, X., Lan, X., Zhang, Y., Qiang, Y., and He, Y. (2020). Incorporation of electroconductive carbon fibers to achieve enhanced anti-corrosion performance of zinc rich coatings. J. Colloid Interface Sci. 567: 113–125, https://doi.org/10.1016/j.jcis.2020.02.002.Search in Google Scholar PubMed
Gergely, A., Bertoti, I., Torok, T., Pfeifer, E., and Kalman, E. (2013). Corrosion protection with zinc-rich epoxy paint coatings embedded with various amounts of highly dispersed polypyrrole-deposited alumina monohydrate particles. Prog. Org. Coating 76: 17–32, https://doi.org/10.1016/j.porgcoat.2012.08.005.Search in Google Scholar
Gharbi, O., Thomas, S., Smith, C., and Birbilis, N. (2018). Chromate replacement: what does the future hold?. NPJ Mater. Degrad. 12: 1–8.10.1038/s41529-018-0034-5Search in Google Scholar
Gupta, A. and Srivastava, C. (2018). Optimum amount of graphene oxide for enhanced corrosion resistance by Tin-graphene oxide composite coatings. Thin Solid Films 661: 98–107, https://doi.org/10.1016/j.tsf.2018.07.016.Search in Google Scholar
Gupta, A. and Srivastava, C. (2019a). Correlation between microstructure and corrosion behaviour of SnBi-graphene oxide composite coatings. Surf. Coating Technol. 375: 573–588, https://doi.org/10.1016/j.surfcoat.2019.07.060.Search in Google Scholar
Gupta, A. and Srivastava, C. (2019b). Enhanced corrosion resistance by SnCu-graphene oxide composite coatings. Thin Solid Films 669: 85–95, https://doi.org/10.1016/j.tsf.2018.10.036.Search in Google Scholar
Horvick, E.W. (1959). Zinc in the world of electroplating. Plating 46: 42–48.Search in Google Scholar
Jyotheender, K.S., Gupta, A., and Srivastava, C. (2020). Grain boundary engineering in Ni-carbon nanotube composite coatings and its effect on the corrosion behaviour of the coatings. Materialia 9: 100617, https://doi.org/10.1016/j.mtla.2020.100617.Search in Google Scholar
Kanagalasara, V. and Venkatesha, T.V. (2011). Studies on electrodeposition of Zn-MoS2 nanocomposite coatings on mild steel and its properties. J. Solid State Electrochem. 16: 993–1001, https://doi.org/10.1007/s10008-011-1475-8.Search in Google Scholar
Katayama, H. and Kuroda, S. (2013). Long-term atmospheric corrosion properties of thermally sprayed Zn, Al and Zn–Al coatings exposed in a coastal area. Corrosion Sci. 76: 35–41, https://doi.org/10.1016/j.corsci.2013.05.021.Search in Google Scholar
Kavitha, B., Santhosh, P., Renukadevi, M., Kalpana, A., Shakkthivel, P., and Vasudevan, T. (2006). Role of organic additives on zinc plating. Surf. Coating Technol. 201: 3438–3442, https://doi.org/10.1016/j.surfcoat.2006.07.235.Search in Google Scholar
Krishnamurthy, S. (1982). Chromate conversion coating on Zinc plating. Proc. Indian Natl. Sci. Acad. 48: 525–526.Search in Google Scholar
Kumar, C.M.P., Venkatesha, T.V., and Chandrappa, K.G. (2012). Effect of surfactants on co-deposition of B4C nanoparticles in Zn matrix by electrodeposition and its corrosion behavior. Surf. Coating Technol. 206: 2249–2257.10.1016/j.surfcoat.2011.09.075Search in Google Scholar
Kumar, M.K.P., Singh, M.P., and Srivastava, C. (2015). Electrochemical behavior of Zn–graphene composite coatings. RSC Adv. 5: 25603–25608, https://doi.org/10.1039/c5ra09936f.Search in Google Scholar
Kumar, M.K.P., Rekha, M.Y., Agrawal, J., Agarwal, T.M., and Srivastava, C. (2019a). Microstructure, morphology and electrochemical properties of ZnFe-Graphene composite coatings. J. Alloys Compd. 783: 820–827.10.1016/j.jallcom.2018.12.354Search in Google Scholar
Kumar, C.N.S., Konrad, M., Chakravadhanula, V.S.K., Dehm, S., Wang, D., Wenzel, W., Krupkeab, R., and Kubel, C. (2019b). Nanocrystalline graphene at high temperatures: insight into nanoscale processes. Nanoscale Adv. 1: 2485–2494, https://doi.org/10.1039/c9na00055k.Search in Google Scholar
Lee, H.C., Liu, W.-W., Chai, S.-P., Mohamed, A.R., Aziz, A., Khe, C.-S., Hidayaha, N.M.S., and Hashim, U. (2017). Review of the synthesis, transfer, characterization and growth mechanisms of single and multilayer graphene. RSC Adv. 7: 15644–15693, https://doi.org/10.1039/c7ra00392g.Search in Google Scholar
Li, R., Liang, J., Hou, Y., and Chu, Q. (2015). Enhanced corrosion performance of Zn coating by incorporating graphene oxide electrodeposited from deep eutectic solvent. RSC Adv. 5: 60698–60707, https://doi.org/10.1039/c5ra11577a.Search in Google Scholar
Li, W., Fan, Z., Li, X., Jiang, B., Yan, F., Zhang, Z., and Wang, X. (2019). Improved anti-corrosion performance of epoxy zinc rich coating on rusted steel surface with aluminum triphosphate as rust converter. Prog. Org. Coating 135: 483–489, https://doi.org/10.1016/j.porgcoat.2019.06.049.Search in Google Scholar
Meshram, A.P., Kumar, M.K.P., and Srivastava, C. (2020). Enhancement in the corrosion resistance behaviour of amorphous Ni-P coatings by incorporation of graphene. Diam. Relat. Mater. 105: 107795, https://doi.org/10.1016/j.diamond.2020.107795.Search in Google Scholar
Musiani, M. (2000). Electrodeposition of composites: an expanding subject in electrochemical materials science. Electrochim. Acta 45: 3397–3402, https://doi.org/10.1016/s0013-4686(00)00438-2.Search in Google Scholar
Ohba, M., Scarazzato, T., Espinosa, D.C.R., and Panossian, Z. (2019). Study of metal electrodeposition by means of simulated and experimental polarization curves: zinc deposition on steel electrodes. Electrochim. Acta 309: 86–103, https://doi.org/10.1016/j.electacta.2019.04.074.Search in Google Scholar
Olad, A. and Rasouli, H. (2010). Enhanced corrosion protective coating based on conducting polyaniline/zinc nanocomposite. J. Appl. Polym. Sci. 115: 2221–2227, https://doi.org/10.1002/app.31320.Search in Google Scholar
Parka, I.l.-C. and Kim, S.-J. (2020). Determination of corrosion protection current density requirement of zinc sacrificial anode for corrosion protection of AA5083-H321 in seawater. Appl. Surf. Sci. 509: 145346, https://doi.org/10.1016/j.apsusc.2020.145346.Search in Google Scholar
Peshova, M., Bachvarov, V., Vitkova, St., Atanasova, G., and Boshkov, N. (2018). Electrodeposited zinc composite coatings with embedded carbon nanotubes - advanced composite materials for better corrosion protection. T I Met. Finish. 96: 324–331, https://doi.org/10.1080/00202967.2018.1520486.Search in Google Scholar
Prasai, D., Tuberquia, J.C., Harl, R.R., Jennings, G.K., and Bolotin, K.I. (2012). Graphene: corrosion-inhibiting coating. ACS Nano 6: 1102–1108, https://doi.org/10.1021/nn203507y.Search in Google Scholar PubMed
Praveen, B.M., Venkatesha, T.V., Naik, Y.A., and Prashantha, K. (2007). Corrosion studies of carbon Nanotubes-Zn composite coating. Surf. Coating Technol. 201: 5836–5842, https://doi.org/10.1016/j.surfcoat.2006.10.034.Search in Google Scholar
Praveen, B.M. and Venkatesha, T.V. (2009a). Electrodeposition and properties of Zn–Ni–CNT composite coatings. J. Alloys Compd. 482: 53–57, https://doi.org/10.1016/j.jallcom.2009.04.056.Search in Google Scholar
Praveen, B.M. and Venkatesha, T.V. (2009b). Generation and corrosion behavior of Zn-nano sized carbon black composite coating. Int. J. Electrochem. Sci. 4: 258–266.Search in Google Scholar
Rahman, G., Najaf, Z., Mehmood, A., Bilal, S., Shah, Au.H.A., Mian, S.A., and Ali, G. (2019). An overview of the recent progress in the synthesis and applications of carbon nanotubes. C-J. Carbon Res. 5: 3, https://doi.org/10.3390/c5010003.Search in Google Scholar
Ranganatha, S., Venkatesha, T.V., Vathsala, K., and Kumar, M.K.P. (2012). Electrochemical studies on Zn/nano-CeO2 electrodeposited composite coatings. Surf. Coating Technol. 208: 64–72, https://doi.org/10.1016/j.surfcoat.2012.08.004.Search in Google Scholar
Raza, M.A., Ali, A., Ghauri, F.A., Aslam, A., Yaqoob, K., Wasay, A., Raffi, M., and Ahmad, R. (2017). Electrochemical behavior of graphene coatings deposited on copper metal by electrophoretic deposition and chemical vapour deposition. Surf. Coating Technol. 332: 112–119, https://doi.org/10.1016/j.surfcoat.2017.06.083.Search in Google Scholar
Rekha, M.Y., Kamboj, A., and Srivastava, C. (2017). Electrochemical behaviour of SnZn-graphene oxide composite coatings. Thin Solid Films 636: 593–601, https://doi.org/10.1016/j.tsf.2017.07.004.Search in Google Scholar
Rekha, M.Y., Kamboj, A., and Srivastava, C. (2018). Electrochemical behaviour of SnNi-graphene oxide composite coatings. Thin Solid Films 653: 82–92, https://doi.org/10.1016/j.tsf.2018.03.020.Search in Google Scholar
Rekha, M.Y. and Srivastava, C. (2019a). Microstructure and corrosion properties of zinc-graphene oxide composite coatings. Corrosion Sci. 152: 234–248.10.1016/j.corsci.2019.03.015Search in Google Scholar
Rekha, M.Y. and Srivastava, C. (2019b). Microstructural evolution and corrosion behaviour of ZnNi-graphene oxide composite coatings. Metall. Mater. Trans. 50: 5896–5913, https://doi.org/10.1007/s11661-019-05474-9.Search in Google Scholar
Shen, X., Sheng, J., Xu, Q., and Cheng, D. (2018). The corrosion behavior of Zn/graphene oxide composite coatings fabricated by direct current electrodeposition. J. Mater. Eng. Perform. 27: 3750–3761, https://doi.org/10.1007/s11665-018-3461-0.Search in Google Scholar
Shibli, S.M.A. and Chacko, F. (2008). Development of nano CeO2-incorporated high performance hot-dip zinc coating. Surf. Coating Technol. 202: 4971–4975, https://doi.org/10.1016/j.surfcoat.2008.04.090.Search in Google Scholar
Song, G., Li, S., Liu, G., Fu, Q., and Pan, C. (2018). Influence of graphene oxide content on the Zn-gr composite layer prepared by pulse reverse electro-plating. J. Electrochem. Soc. 65: D501–D510, https://doi.org/10.1149/2.0431811jes.Search in Google Scholar
Tseluikin, V.N. and Koreshkova, A.A. (2014). Deposition of zinc–carbon nanotube composite coatings in the pulse-reverse mode. Russ. J. Appl. Chem. 87: 1251–1253, https://doi.org/10.1134/s1070427214090109.Search in Google Scholar
Vereecken, P.M., Shao, I., and Searson, P.C. (2000). Particle codeposition in nanocomposite films. J. Electrochem. Soc. 147: 2572–2575, https://doi.org/10.1149/1.1393570.Search in Google Scholar
Vlasa, A., Varvara, S., Pop, A., Bulea, C., and Muresan, L.M. (2010). Electrodeposited Zn-TiO2 nanocomposite coatings and their corrosion behavior. J. Appl. Electrochem. 40: 1519–1527, https://doi.org/10.1007/s10800-010-0130-x.Search in Google Scholar
Wang, C.B., Wang, D.L., Chen, W.X., and Wang, Y.Y. (2002). Tribological properties of nanostructured WC/CoNi and WC/CoNiP coatings produced by electro-deposition. Wear 253: 563–571, https://doi.org/10.1016/s0043-1648(02)00173-4.Search in Google Scholar
Wortelen, D., Frieling, R., Bracht, H., Graf, W., and Natrup, F. (2015). Impact of zinc halide addition on the growth of zinc-rich layers generated by sherardizing. Surf. Coating Technol. 263: 66–77, https://doi.org/10.1016/j.surfcoat.2014.12.051.Search in Google Scholar
Wu, H., Ding, G., Wang, Y., Cao, Y., Wang, H., and Yang, C. (2006). Composite electrodeposition of Zinc and Carbon nanotubes. In: Proceedings of the 1st IEEE international conference on Nano/Micro Engineered and Molecular Systems, IEEE, China, https://doi.org/10.1109/nems.2006.334798.Search in Google Scholar
Yadav, A., Kumar, R., Choudhary, H.K., and Sahoo, B. (2018). Graphene-oxide coating for corrosion protection of iron particles in saline water. Carbon 140: 477–487, https://doi.org/10.1016/j.carbon.2018.08.062.Search in Google Scholar
Yang, B., Zhang, P., Wang, G., Wang, A., Chen, X., Wei, S., and Xie, J. (2019). Effect of graphene oxide concentration in electrolyte on corrosion behavior of electrodeposited Zn-electrochemical reduction graphene composite coatings. Coatings 9: 758, https://doi.org/10.3390/coatings9110758.Search in Google Scholar
© 2020 Walter de Gruyter GmbH, Berlin/Boston
