The effects of duty cycles on pulsed current electrodeposition of ZnNiAl2O3 composite on steel substrate: Microstructures,hardness and corrosion resistance

In this study, we examine the effect of duty cycles (33%, 50% and 67%) under square-wave galvanostatic pulses on the electrodeposition of zinc-nickel-alumina (ZnNiAl₂O₃) composites from a sulfate bath. XRD results showed that the dominant phases of the ZnNiAl₂O₃ electrodeposits were mixtures of Zn₂₁Ni₅ and Zn₂₂Ni₃ phases together with as Al₂O₃. The Ni content measured in the electrodeposits using EDS varied from 9.73 to 13.47 wt%. SEM results showed that finer and smoother surface electrodeposits were obtained by pulsed current electrodeposition at a low (33%) duty cycle. In addition, the corrosion properties of the electrodeposits were characterized by Tafel plots and electrochemical impedance spectroscopy (EIS), while the microhardness of the electrodeposits was measured by a Vickers hardness tester. In summary, this study revealed that pulsed current electrodeposition at a 33% duty cycle led to a finer and smoother surface morphology, an enhanced strength, a greater corrosion resistance, and a higher Ni content in the ZnNiAl₂O₃ composite coatings compared to plating at higher duty cycles or plating through DC electrodeposition.