Molten salt electrodeposition of aluminum on mild steel: effect of process parameters on surface morphology and corrosion properties

Abstract The electrodeposition of aluminum on mild steel in a molten salt electrolyte consisting of a mixture of AlCl 3 /NaCl/KCl (weight percent ratio of 80:10:10) was studied. Parametric studies were carried out to evaluate the effect of different parameters such as current density, electrolysis time, and intermediate coating layer on the coating morphology and coating-to-substrate adhesion. The quality and morphology of the coating were investigated using scanning electron microscope (SEM) and x-ray map analyses. The effect of heat treatment of the coated samples on the interface stability and formation of intermetallic compounds at the Al-Fe interface was also investigated. Cross-sectional examination by SEM as well as energy dispersive spectroscopy (EDS) line scan showed that upon annealing at temperatures in the range of 350 °C–550 °C, brittle Fe-Al intermetallic layers were formed at the interface. This shows that high-temperature service conditions can adversely affect the coating properties. The apparent activation energy of the formation of such intermetallic layers was calculated based on thickness measurements on these layers. The optimum conditions for electroplating were determined as current density of 0.022 A.cm −2 and electroplating time of 60 min. Potentiodynamic polarization tests were used to evaluate the corrosion resistance of the samples in 3.5 wt% NaCl solution. Considering the corrosion rate of coated samples which is much lower than the bare substrate, it was concluded that the electrodeposited coatings could efficiently protect the steel substrate against corrosion in corrosive media.