Strategic Development of Ni–Cu–Fe2O3 Composite Coatings to Strengthen Mild Steel Against Corrosion

Abstract

AbstractMild steel is extensively employed in various industries due to its affordability and versatility. However, its susceptibility to corrosion poses a significant challenge. This study explores the efficacy of protecting mild steel by applying coatings composed of highly noble copper and its alloys. In this direction, Ni–Cu alloy and Ni–Cu–Fe2O3 coating have been developed from a sulfate citrate bath on mild steel through the electrodeposition method. The alloy and composite coating deposition was done at different current densities 1 A dm−2, 2 A dm−2, 3 A dm−2, and 4 A dm−2. The copper content of the coating has increased with an increase in current density in both alloy and composite coatings. The deposit with a high Copper content showed lower crystallite size with a lower corrosion rate value at a current density of 3 A dm−2. The trace addition of Fe2O3 into the Ni–Cu alloy matrix has improved the overall corrosion resistance of the mild steel materials as compared to bare Ni–Cu alloy coating.