Optimization of phosphate coating properties on steel sheet for superior paint performance

The adhesion of electrodeposition (ED) paint on steel sheets for automobiles is highly influenced by the properties of the zinc phosphate coating which is used to improve its corrosion resistance. In the present study, a steel surface was pretreated with two types of zinc phosphate formulations followed by ED painting. The surface morphology, crystal plane, and porosity properties of phosphate coating on steel samples were studied by scanning electron microscope, X-ray diffraction, and electron probe microanalyzer, respectively. The corrosion resistance of painted samples was evaluated by an accelerated corrosion test as well as by electrochemical techniques like cathodic disbonding and AC?CDC?CAC tests. The phosphate coating enriched with a phosphophyllite structure showed small globular crystals with less porosity, whereas a hopeite structure showed coarse crystals with high porosity and comparatively thicker coating. The maximum corrosion resistance was observed in the painted sample, where the phosphate coating comprised a phosphophyllite structure. On the other hand, the painted samples phosphated with a predominantly hopeite structure showed inferior corrosion resistance performance. The unphosphated sample showed severe degradation in paint adhesion and corrosion resistance, which substantiates the importance of phosphate pretreatment.