Optimizing the defensive characteristics of mild steel via the electrodeposition of ZnSi3N4 reinforcing particles

The effect of ZnSi₃N₄ deposition prepared via direct electrolytic co-deposition on mild steel was studied as a result its inherent vulnerability to corrosion in an aggressive environment and failure on the application of load. The experiment was conducted varying the mass concentration of silicon nitride (Si₃N₄) between 7 and 13 g at cell voltage of 0.3 and 0.5 V, at constant temperature of 45 °C. The morphologies of the coated surfaces were characterized using high resolution Nikon Optical Microscope and Scanning Electron Microscope (SEM) revealing that the particles of the ZnSi₃N₄ were homogeneously dispersed. The corrosion behaviour was studied using potentiodynamic polarization technique in 3.65% NaCl solution and the microhardness was examined using Brinell hardness testing technique. The result of the corrosion experiment confirmed an improved corrosion resistance with a reduction in corrosion rate from 9.7425 mm/year to 0.10847 mm/year, maximum coating efficiency of 98.9%, maximum polarization resistance of 1555.3 Ω and a very low current density of 9.33 × 10^?6 A/cm². The negative shift in the E_corr revealed the cathodic protective nature of the coating. The microhardness was also found to have increased from 137.9 HBN for the unmodified steel to a maximum value of 263.3 HBN for the 0.5Zn13Si₃N₄ coated steel representing 90.9% increment in hardness as a result of the matrix grain refining and dispersion-strengthening ability of the incorporated Si₃N₄ particles.