Corrosion Behaviour of Nanocrystalline Zn-Ni and Zn-Ni-Co Electrodeposits

In this study, alternatives to corrosion-resistant cadmium coatings on high strength steel fasteners are explored. Nanocrystalline Zn-Ni and Zn-Ni-Co electrodeposits, synthesized by electrochemical deposition, were analyzed by potentiodynamic polarization in a 1M NaCl aqueous solution, to determine the corrosion behaviour of the alloys. Sample coatings were characterized using scanning electron microscopy to examine differences in surface morphology that can affect corrosion resistance. Energy dispersive x-ray spectroscopy was used to relate composition to corrosion resistance and to characterize the corrosion behavior during polarization. All coatings showed corrosion potentials at equivalent, or lower values than that of cadmium, suggesting that both alloys are viable as cadmium replacements. Specific compositions showed slightly passivating regions, but the brittle film formed during polarization is unstable. Comparatively, Zn-Ni shows a better resistance to corrosion than Zn-Ni-Co. The effect of composition on the corrosion resistance can be explained on the basis of the sacrificial depletion of Zn over Ni.