Characteristics Study of Mild Steel Electro-plated with Light Weight Zn-Si3N4 Nanocomposite

In most industries, Lightweighting has become a popular concept. Production of low-density components is presently seen as a technique for achieving improved handling and efficiency in manufacturing industries. Thus, low-density Si 3 N 4 ceramic particles were introduced into the matrix of zinc to produce low-density Zn-Si 3 N 4 nanocomposite films. After preliminary experimental runs, Zn-Si 3 N 4 nanocomposite coated mild steel samples were produced at 0.3 and 0.5 V, and at an invariable temperature of 45 o C. The mass concentration of Si 3 N 4 ceramic particles varied between 7 and 13 g L − 1 . The corrosion rate (CR) of the coatings was examined through the potentiodynamic polarization method in 0.5 M of sulphuric acid solution, while the coatings’ microstructure was studied using XRD and SEM. The wear volume (WV) and coefficient of friction (COF) of coated samples and an uncoated sample were investigated using a pin-on-disc tribometer. The samples’ electrical conductivity was studied using simple ammeter-voltmeter equipment. The potentiodynamic polarization test results signified that the thin films reduced the CR of mild steel from 12.3450 mm year − 1 to 2.6793 mm year − 1 , indicating noteworthy passivation of the films. The refined morphology of the coated surfaces as revealed by the SEM micrographs was ascribed to the dissolution and dispersion of nanoparticles. The XRD crystallographic phases of the coated samples also showed that the thin films possessed excellent texture, high stability and chemical homogeneity, and. More so, the coated mild steel samples exhibited lower COF relative to the uncoated sample. The thin film reduced the WV of the mild steel from 0.00508 mm 3 to 0.00266 mm 3 , which indicated that strengthening mechanisms existed between the steel and the coating interface. The electrical conductivity test further shows that the Zn-Si 3 N 4 film reduced the electrical conductivity of mild steel from12.97 Ω −1 cm −1 to 0.64 Ω −1 cm −1 .