ENVIRONMENTALLY FRIENDLY ALUMINUM COATINGS AS SACRIFICIAL COATINGS FOR HIGH STRENGTH STEEL ALLOYS

Electroplating process is described for coating a ferrous alloy steel cathode substrate with an aluminum coating, the process comprises: a) immersing an aluminum anode substrate in a plating bath formulation comprising: a source of aluminum, an ionic liquid, a brightening agent, and a metal-salt compound; b) etching the cathode substrate by immersing it into the aluminum plating bath and conducting an anodic polarization step; c) electroplating the etched cathode substrate with the aluminum plating bath formulation; and d) rinsing with alcohol and water, and drying. Preferably, the process further comprises a heat treatment applied to the aluminum coated ferrous steel alloy obtained in step d).