Production of layered coatings of Fe-Ni alloy for enhanced corrosion protection

Abstract

Layered Fe-Ni alloy coatings have been galvanostatically developed on copper using dual and triple square current pulse from acid sulfate bath. The cyclic cathode current density (CCCD) and number of layers have been optimized for enhanced performance of the coatings against corrosion. Corrosion behavior of the coatings is evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy methods in 1 M HCl solution. The polarization study confirms that coatings developed using triple square pulses are more corrosion resistant than those deposited by dual square pulses. The improved corrosion behavior of layered coatings is due to the changed intrinsic electric properties evidenced by the electrochemical impedance spectroscopy. Under optimal conditions, the coatings developed using dual and triple square current pulse have been found to be by about 23 and 57 times, respectively, more corrosion resistant than the monolithic alloys. Surface morphology and layered coatings have been examined by scanning electron microscopy. Saturation of corrosion resistance at a high degree of layering was found, which is attributed to a shorter relaxation time for redistribution of metal ions during plating. 2013 Allerton Press, Inc.