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<p>Zn-Ni alloy coating has emerged as a promising alternative to pure Zn coating because of its superior corrosion resistance. In this study, high-quality Zn-Ni alloy coatings with enhanced corrosion resistance were successfully electrodeposited by regulating the NiSO<sub>4</sub>·7H<sub>2</sub>O concentration in the plating baths and employing the ultrasound assistance. The phase structures, compositions, surface morphologies, and corrosion behaviors of the electrodeposited coatings were investigated by x-ray diffraction (XRD), energy-dispersive x-ray spectroscopy (EDS), scanning electron microscopy (SEM), potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS), respectively. Among all samples, the Zn-Ni 75 US coating, prepared with ultrasonic assistance in a bath containing 0.075&#xa0;mol L<sup>-1</sup> NiSO<sub>4</sub>·7H<sub>2</sub>O, exhibited the optimal corrosion resistance, demonstrated by its lowest corrosion current density (<i>i</i><sub>corr</sub>: 8.7 μA cm<sup>-2</sup>) and the highest electrochemical impedance resistance (<i>R</i><sub>total</sub>: 3848.9 Ω·cm<sup>-2</sup>). These improvements can be attributed to the synergistic effects of ultrasonic assistance and bath concentration optimization, which increase Ni content, refine grain size, and modify surface morphology. The work highlights the significant role of ultrasonic assistance in electrodepositing high-performance Zn-Ni alloy coatings for corrosion protection applications.</p>

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Ultrasonic-Assisted Electrodeposition of Zn-Ni Alloy Coatings for Improving the Corrosion Resistance

  • 期刊论文

  • 发表日期：

    2026年2月20日

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  • Xi Shi,
  • Tongjun Wu,
  • Zihao Nie,
  • Qianjun Deng,
  • Changchun Tian,
  • Xiaoliang Yan,
  • Qiongyu Zhou

摘要

Zn-Ni alloy coating has emerged as a promising alternative to pure Zn coating because of its superior corrosion resistance. In this study, high-quality Zn-Ni alloy coatings with enhanced corrosion resistance were successfully electrodeposited by regulating the NiSO4·7H2O concentration in the plating baths and employing the ultrasound assistance. The phase structures, compositions, surface morphologies, and corrosion behaviors of the electrodeposited coatings were investigated by x-ray diffraction (XRD), energy-dispersive x-ray spectroscopy (EDS), scanning electron microscopy (SEM), potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS), respectively. Among all samples, the Zn-Ni 75 US coating, prepared with ultrasonic assistance in a bath containing 0.075 mol L-1 NiSO4·7H2O, exhibited the optimal corrosion resistance, demonstrated by its lowest corrosion current density (icorr: 8.7 μA cm-2) and the highest electrochemical impedance resistance (Rtotal: 3848.9 Ω·cm-2). These improvements can be attributed to the synergistic effects of ultrasonic assistance and bath concentration optimization, which increase Ni content, refine grain size, and modify surface morphology. The work highlights the significant role of ultrasonic assistance in electrodepositing high-performance Zn-Ni alloy coatings for corrosion protection applications.