The Effect of Potassium Oxalate and Nickel Oxide as Additives on The Structure, Corrosion Resistance and Abrasion Properties of Manganese Phosphate Coating

Document Type : Original Article

Authors

Faculty of Applied Chemistry, Malek Ashtar University of Technology, Isfahan

Abstract

During this research, the formulation of manganese phosphate bath was designed to create layers on the surface of low carbon steel alloys (St 37) to enhance corrosion, abrasion and friction resistance. At the first, a basic solution of the manganese phosphate bath was prepared by optimizing the concentration of each components of the bath. Then, the effects of potassium oxalate and nickel oxide additives on coating properties such as thickness, unit weight of surface (With optimal value of 1± 0.1 gr/l nickel oxide, the weight of the coating 39.8 ± 0.2 gr/m was obtained and optimal value of 0.5±0.1 gr/l potassium oxalate, the weight of the coating 48.99±0.3 gr/m2 was obtained), morphology, corrosion and abrasion resistance were investigated and finally, the best coating determined.The results of various experiments showed that the major phase of manganese phosphate coating is Hureaulite, which is in the form of cubic crystals in the basic solution that does not contain any additives, of course, with the addition of additives, the shape of the crystals is changed and the particle size becomes smaller and denser. The highest corrosion resistance obtained during the salt spray test (98 hours) and electrochemical impedance spectroscopy (EIS) (with Polarization 77983±253) is related to phosphate coating containing nickel oxide. According to the results of the Pin on disk test the specimens which were phosphated and soaped reduced the coefficient of surface friction from about 0.6 (for uncoated steel) to about 0.15, and this indicated the anti-abrasion and friction properties of these coatings.

Keywords


  1. D. B. Freeman, Phosphating & metal pretreatment, a guid to modern process & practice, industrial press inc. New York, 1986.
  2. M. A. Streicher, Corrosion protection by phosphatization – A Review. Corros. 4(1946), 219-227.
  3. D. Weng, P. Jokiel, A. Uebleis, H. Bochni, Corrosion and protection characteristics of zinc and manganese phosphate coating. Surf. Coat. Technol. 88(1997), 147-156.
  4. J. E. Gray, B. Luan, J., Protective coatings on magnesium and its alloys. a critical review. Alloys Compd. 18 (2002), 88-113.
  5.  L. Kouisni, M. Azzi, M. Zertoubi, F.Dalard, S. Maximovitch, Phosphate coatings on magnesium alloy AM60 part 1: study of the formation and the growth of zinc phosphate film.Surf. Coat. Technol. 185(2004), 58-67
  6. K. Woods, S.Spring, Zinc Phosphating. Met. Finish. 77(1979), 56-60.
  7. P. Hivart, B. Hauw, J.P. Bricout, J. Oudin, Seizure behavior of manganese phosphate coating according to the process conditions. Tribol. Int. 30(1997), 561-570.
  8. A. Talaat El-Mallah, M. Hassib Abbas, Trends in phosphating of metals Part II – Iron and manganese phosphating, bath control and testing of the coatings. Finish. 11(1987), 22-27.
  9. L. Fanga, L. Xiea, J.Hua, Y. Lia, W. Zhang, Study on the growth and corrosion resistance of manganese phosphate coatings on 30CrMnMoTi alloy steel. Physics Procedia. 18(2011) 227–233.

10.S. Shanmugam, K. Ravichandran, T. S. N. Sankara Narayanan, Min Ho Lee, A facile electrochemical approach for the deposition of iron-manganese phosphate composite coatings on aluminium. RSC Adv. 8(2015) 988-1008.

11.W. J. Gilbert, R. J. Chironna, Metals Handbook, Corrosion of emission-control equipment. Corrosion, United States. 1987, 1367-1370

12.K.Woods and S.Spring, Selection of a paint peretreament system. Metal Finish. 76(1978), 17-22.

13.R. D. E. L. Bridger, Progress in zinc phosphating. Finish. Ind. 10(1980), 24-28.

14.Wittke W. J., Phosphate coating, metal finishing, 1980.

15.L. Y. Niu, Z. H. Jiang, G. Y. Li, C. D. Gu, J. S. Lian, A study and application of zinc phosphate coating on AZ91D magnesium alloy. Surf. Coat. Technol. 200(2006), 3021–3026.

16. ا. متین محمدی، م. محمدزاده عطار، ب. رمضان‏زاده کراتی، مطالعه خواص ضد خوردگی، ریخت‌شناسی و چسبندگی پوشش فسفاته دمای محیط حاوی افزودنی کبالت. نشریه علمی علوم و فناوری رنگ. (1393) 8، 228-221.

17. ل. فتح یونس، م. آزادبه، تاثیر روش‏های مختلف فعال‏سازی مکانیکی سطح فولاد ساده کربنی بر ساختار پوشش فسفاته روی و کیفیت چسبندگی رنگ. نشریه علمی علوم و فناوری رنگ. (1393) 8، 25-13.

18.H. Zhang, G. Yao, Sh. Wang, A chrome-free conversion coating for magnesium–lithium alloy by a phosphate– permanganate solution. Surf. Coat. Technol. 202(2008),1825-1830.

19.D. Susac, X. Sun, R.Y. Li, Microstructural effects on the initiation of zinc phosphate coatings on 2024-T3 aluminum alloy. Appl. Surf. Sci. 239(2004), 45-59.

20.Z. Shenglin, Study on phosphating treatment of aluminum, alloy role of yttrium oxide. J. rare earths. 27(2009), 469- 480.

21.M. Sheng, Ch. Wanga, Q. Zhong, Ultrasonic irradiation and its application for improving the corrosion resistance of phosphate coatings on aluminum alloys. Ultrason.Sonochem. 17(2010), 21-25.

22.G.Y. Li, J. S. Lian, L.Y. Niu, Growth of zinc phosphate coatings on AZ91D magnesium alloy. Surf. Coat. Technol.201(2006), 1814-1820.

23.W. Rausch, The phosphating of metals, Finishing publications Ltd, England, 1990.

24.S. Shanmugam, K. Ravichandran, T. S. N. Sankara Narayanan and M. Marappan, Development of permanganate assisted manganese phosphate coating on mild steel. Corros. Eng. Sci. Technol. 10(2014), 719-726.

25.R. Thomas, M. J. Umapathy, Nano silicon dioxide accelerated zinc phosphate conversion coating on mild steel using decyltriethylammonium bromide as an additive. Silicon. 7(2015), 371–381.

26.F. El-Taib Heakal, N. S. Tantawy, O. S. Shehata, Impact of chloride and fluoride additions on surface reactivity and passivity of AM60 magnesium alloy in buffer solution. Corros. Sci. 64(2012), 153–163.

27.X. Cui, Ch. Liu, R.Yang, Q. Fu, X.Lin, M. Gong, Duplex-layered manganese phosphate conversion coating onAZ31 Mg alloy and its initial formation mechanism.Corros. Sci. 76(2013), 474–485.

28.S. Ilaiyavel, A. Venkatesan, Experimental investigation of wear characteristics on manganese phosphate coated AISI D2 steel, Int. J. Precis. Eng. Manufacturing. 13(2012), 581-586.

29. ر. امینی، ع.ا. سرابی، س.م. کثیری‌ها، تاثیر سدیم دودسیل سولفات بر ساختار و خواص ضد خوردگی پوشش فسفاته بر روی آلیاژ منیزیم AZ31. نشریه علمی علوم و فناوری رنگ. (1389) 4، 189-183.

30.S. Azhaarudeen, A. A. M. Faruck, A. Nevosad, Tribological behavior and wear mechanisms of manganese phosphate coatings under dry reciprocating sliding contact conditions. Tribol. Int. 122(2018), 189-199.

31.Machu, Die-phosphatierung, Verlag Chemie, 1950.

32.Standard Test Method for Wear Testing with a Pin- on -Disk Apparatus, ASTM Standard, G99-17, 2017.

33.M.C.M. Farias, C.A.L. Santos, Z. Panossian, A. Sinatora, Friction behavior of lubricated zinc phosphate coatings. Wear. 266(2009), 873-877.

34. ع. خلج‏زاده، استانداردهای فسفاته‏کاری و سیاه‌کاری فلزات، انجمن صنایع آبکاری ایران(1392).

35.Standard Practice for Operating Salt Spray (Fog) Apparatus, ASTM Standard, B117–11, 2011.

36.F. Pastorek, K. Borko, S. Fintova, D. Kajanek, B. Hadzima, Effect of surface pretreatment on quality and electrochemical corrosion properties of manganese phosphate on S355J2 HSLA Steel. Coat. 6(2016),46-55.

37. M. D. Carattino, Effects of long-term exposure to Cu2+ and Cd2+ on the pentose phosphate. Ecotoxicol. Environ. Saf. 57(2004), 311-318.