Investigation of a Hydrophobic and Sustainable Multifaceted Coating for Enhanced Service Life of Steel

Surface modification techniques are vital for improving material properties and performance in a wide range of applications. This study looks at the development and efficacy of ZnO-MgO coatings on mild steel substrates with various concentrations of snail shell particles (SSP). The coatings were evaluated for anti-corrosion resistance, electrical characteristics, surface morphology, and hardness to determine their suitability for industrial applications. Corrosion investigation shows that coated samples have substantially lower corrosion rates (CR) and current densities (J_corr) than the as-received sample, with ZnO-MgO-20SSP showing the strongest corrosion resistance (J_corr: 2.19 × 10² A/cm², CR: 14.68 µm/yr). ZnO-MgO-20SSP had the lowest resistivity (3.32 Ωm) and the maximum conductivity (0.3012 (Ωm)⁻¹). SEM/EDS investigation reveals different morphologies, with ZnO-MgO-20SSP exhibiting well-dispersed SSP clusters, which contribute to improved mechanical characteristics. XRD examination reveals the presence of favourable phases, which contribute to increased corrosion resistance and mechanical stability. Additionally, hardness testing shows that coated materials have improved resistance to mechanical stress and surface wear.