Effect of Ni Concentration on the Surface Morphology and Corrosion Behavior of Zn-Ni Alloy Coatings

This research work aims to develop electrodeposited Zn-Ni alloy coatings with controlled dissolution tendencies on a mild steel substrate. The varying Ni concentration in the electroplating bath, i.e., 10, 15, 20 and 25 g·L−1, affected the surface morphology and electrochemical properties of the deposited Zn-Ni alloy coatings. SEM and EDS analysis revealed the resulting variation in surface morphology and composition. The electrochemical behavior of different coatings was evaluated by measuring the open circuit potential and cyclic polarization trends in 3.5 wt.% NaCl solution. The degradation behavior of the electrodeposited Zn-Ni coatings was estimated by conducting a salt spray test for 96 h. The addition of Ni in the coating influenced the coating thickness and surface morphology of the coatings. The coating thickness decreased from 38.2 ± 0.5 μm to 20.7 ± 0.5 μm with the increase in Ni concentration. Relatively negative corrosion potential (