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DOI: 10.1002/maco.201407633
1 Introduction
Corrosion resistance, superior mechanical properties, and low
maintenance costs are resulted in applying hotdip galvanized
steels in variant elds such as automobiles, construction
structures, transportation, etc. [14]. The corrosion rate of Zn
is high due to the large potential difference between iron
substrate and zinc layer [5,6]. It is well known that chromate
coatings are very effective anticorrosives and inhibitors with self
healing property [7,8]. However, due to toxicity and carcinogenic
effects of chromate coatings, there have been extensive efforts in
order to nd an appropriate alternative for it [912]. Rare earth
elements, titanium salts, permanganate, and molybdatephosphatesilanesilicate (MPSS) have been investigated as alternative
for chromate conversion coating on HDG. But their performances were not sufcient in comparison with commercial
chromate conversion coatings and it was necessary to investigate
new compounds [1318].
Many studies show that silicate provides environmental
friendly and good corrosion resistant coatings for the substrate
metals [1924]. Previous researches have described the role of
different processing parameters on the corrosion resistance of
F. Jamali, I. Danaee
Abadan Faculty of Petroleum Engineering, Petroleum University of
Technology, Abadan, (Iran)
E-mail: danaee@put.ac.ir
D. Zaarei
Technical Faculty, South Tehran Branch, Islamic Azad University,
Tehran, (Iran)
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wileyonlinelibrary.com
Rp
with 2030 nm particle size was prepared from Iranian Nanomaterials Pioneers. Potassium silicate solution and nanosilica
colloid were mixed and different silica ratios 2, 3, 4, and 5 were
prepared. Prior to immersion, solutions were agitated by a
magnetic agitator with the velocity of 500 rpm for 30 min at room
temperature. Samples were cured in oven at 100 8C for 30 min.
The coated samples were stored at room temperature for 1 h.
Electrochemical measurements were carried out by Potentiostat/Galvanostat Autolab, model PGSTAT 302N. Electrochemical glass cell contained a reference electrode of Ag/AgCl, an
auxiliary electrode of platinum and a sample of coated HDG as the
working electrode. To provide steady state condition, samples
were stored for 30 min in electrolyte solution before the test. The
scan rate of polarization curves was 0.5 mV/s. The frequency
range of the EIS was 105102 Hz with AC signal amplitude of
10 mV. Fitting of experimental impedance spectroscopy data to
the proposed equivalent circuit was done by means of a home
written least square software based on the Marquardt method for
the optimization of functions and Macdonald weighting for the
real and imaginary parts of the impedance [27,28].
The morphology of the surface was studied by scanning
electron microscopy (SEM, VEGA, TESCANLMU) equipped
with an energydispersive Xray spectroscopy (EDS) probe.
ba bc
1
2:303ba bc I corr
Ratio
Ecorr (V)
Rp (ohm)
Icorr (A/cm2)
bc (V/dec)
ba (V/dec)
CR (mm/year)
HDG
2
3
4
5
0.967
0.926
0.943
0.918
0.932
7.39 103
9.94 103
8.20 104
5.41 103
1.88 103
2.4 106
3.3 107
5.7 108
1.4 106
1.5 106
0.055
0.010
0.012
0.023
0.01
0.159
0.031
0.11
0.085
0.019
2.82 102
3.88 103
6.73 104
1.70 102
1.77 102
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Rc
1=1 Z ct v=Rc ivn Rc Qc
Rct
Z ct v
n
iv Qdl Rct 1
Zv Rs
Sample
HDG
Ratio
Ratio
Ratio
Ratio
Figure 2. Electrochemical impedance spectroscopy diagrams of
potassium silicate coatings of HDG in 5 wt% NaCl solution. Coatings
were obtained from potassium silicate solution in different ratio:
(1) HDG, (2) ratio 2, (3) ratio 3, (4) ratio 4, and (5) ratio 5
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2
3
4
5
Rc (V)
Qc (F)
n1
Rct (V)
Qdl (F)
n2
5.1 103
9.1 103
2.4 104
6.1 103
5.6 103
5 105
4 105
1 105
4 105
3 105
0.65
0.69
0.72
0.67
0.62
1.8 103
1.2 104
4.3 104
1.1 104
4.5 103
3 103
3 104
2 104
4 104
1 103
0.75
0.78
0.82
0.78
0.73
Sample Rc (V)
30 s
60 s
120 s
Qc (F)
n1
Rct (V)
Qdl (F)
n2
cannot release from the coating because of the presence of the top
hard layer and leads to cracking and porous structures.
3.2 Surface analysis
Figure 5. (a) SEM and (b) EDX analysis of the potassium silicate
conversion coating of HDG obtained from potassium silicate with ratio 2
and immersion time 60 s
Figure 6. (a) SEM and (b) EDX analysis of the potassium silicate
conversion coating of HDG obtained from potassium silicate with ratio 3
and immersion time 60 s
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Figure 7. (a) SEM and (b) EDX analysis of the potassium silicate
conversion coating of HDG obtained from potassium silicate with ratio 4
and immersion time 60 s
Figure 8. (a) SEM and (b) EDX analysis of the potassium silicate
conversion coating of HDG obtained from potassium silicate with ratio 5
and immersion time 60 s
4 Conclusions
The corrosion behavior of nanosilica potassium silicate conversion coatings on the HDG was investigated in 5 wt% NaCl
solution. Potassium silicate coatings improve the corrosion
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Ratio
2
3
4
5
Si (wt%)
K (wt%)
15.58
16.39
17.39
21.47
1.05
0.57
0.46
0.30
5 References
[1] G. Ebell, A. Burkert, J. Lehmann, J. Mietz, Mater. Corros.
2012, 63, 791.
W7633
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