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Item Investigation on Corrosion Behavior of Polydimethylsiloxane and Nanofillers-Based Polymer Nanocomposite Coated Galvanized Iron(Springer, 2025) Kumar, P.; Kumar, S.; Ramesh, M.R.; Doddamani, M.The paper focuses on developing polydimethylsiloxane (PDMS) and nanofillers (ZnO and SiO2) based polymer nanocomposite solutions for coating galvanized iron (GI) using sol–gel dip coating method and investigating its corrosion behavior. The nanofillers in varying wt.% (0, 2, 4, 6, 8, and 10) are incorporated in the solution of PDMS and xylene for developing a nanocomposite coating solution. The solutions are characterized by pH, viscosity, and non-volatile matter. It is observed that all the solutions are basic. The viscosity (10.28–47.43%) and the non-volatile matter (8.06–15%) of the solutions are observed to be increasing with an increasing nanofiller % as compared to the base solution (PDMS and xylene). The developed solutions are coated on the GI substrate and tested for wettability, XRD, FTIR, and electrochemical responses. The wettability and the XRD tests confirm the hydrophobic and amorphous nature of the coated surface, respectively. The Si–O–Si groups are observed at 1088 cm−1. The electrochemical analysis shows that the impedance resistance of the coated surfaces is higher than that of the surface coated with the base solution. Further, the corrosion rate of the coated surfaces decreases with the % of the nanofillers. The coating with 10% nanofillers exhibited the highest impedance resistance and the lowest corrosion rate, finding applications in construction, marine, and naval. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.Item Electrodeposition and characterization Zn-Co alloy(2009) Hegde, A.; Thangaraj, V.The present work details optimization of a stable acid chloride bath for electroplating of bright Zn-Co alloy on mild steel using gelatin and glycine as additives. It was found that the addition of gelatin along with glycine changed the deposition pattern markedly. A suitable bath has been formulated using conventional Hull cell experiments. The bath under plating conditions were found to exhibit anomalous codeposition with preferential deposition of less noble (zinc) over more noble (cobalt) as characterized by Zn-Fe group metal alloys. Investigation revealed that the current density (c.d.), temperature, and pH of the bath have strong effect on the composition of the deposit. Influence of bath constituents and operating parameters on appearance and composition of deposits were studied as measure of their performance against corrosion. A variety of deposits were obtained and their corrosion resistances were measured by Tafel method with/without chrome passivation. Experimental results demonstrated the fact that the corrosion resistances of Zn-Co alloys increased with percent of Co in the deposit except at very high c.d. This is due to the fact at very high c.d. the deposit becomes very porous and thick as evidenced by SEM image. The formation of Zn-Co alloy is confirmed by EDAX analysis. A stable chloride bath for Zn-Co alloy deposition has been proposed and discussed. The formation of passive film on chromatization is indicated by almost same E corr value of all Zn-Co electroplates irrespective of the current densities at which they have been deposited. © 2009 Pleiades Publishing, Ltd.Item Assessment of corrosion behavior of ductile irons by factorial experiments(2009) Surendranathan, A.O.; Prabhu, K.N.; Sudhaker Nayak, H.V.The corrosion behavior of unalloyed and alloyed ductile irons (as cast, annealed, and cold worked) in sea water, dilute sulfuric acid, and dilute sodium hydroxide solutions was assessed. Specimen history had a significant effect on the corrosion potential except in ductile iron alloyed with Ni. When the specimens were subjected to different levels of cold working, the corrosion rate was influenced by both the history and the medium. Temperature had a significant effect on the corrosion rate except in the case of unalloyed ductile iron. Factorial experiments indicated that the cold-worked samples were more sensitive to the effect of temperature and composition on the corrosion rate as compared to annealed and as-cast samples. The medium had a significant effect on the corrosion rate in all the cases. © 2009 ASM International.Item Electrolytic preparation of cyclic multilayer Zn-Ni alloy coating using switching cathode current densities(2010) Venkatakrishna, K.; Hegde, A.C.Cyclic multilayer alloy (CMA) coating of Zn-Ni was developed on mild steel using single bath technique, by proper manipulation of cathode current densities. The thickness and composition of the individual layers were altered precisely and conveniently by cyclic modulation of cathode current densities. Multilayer coatings, having sharp change in compositions were developed using square current pulses. Gelatin and sulphanilic acid (SA) acid were used as additives. Laminar deposits with different configurations were produced, and their corrosion behaviors were studied, in 5% NaCl solution by electrochemical methods. It was observed that the corrosion resistance of CMA coating increased progressively with number of layers (up to certain optimal numbers) and then decreased. Cyclic voltammetry study demonstrated the role of gelatin and SA in multilayer coating. The coating configuration has been optimized for the peak performance against corrosion. The substantial decrease of corrosion rate, in the case of multilayer coatings was attributed to the changed intrinsic electric properties, evidenced by Electrochemical Impedance Spectroscopy (EIS) study. The surface morphology and its roughness were examined by Atomic Force Microscopy (AFM). The surface and cross-sectional view of coatings were examined, using Scanning Electron Microscopy (SEM). X-ray photoelectron spectrum (XPS) study was carried out for surface analysis. The relative performance of pure Zn, monolithic and CMA coatings were compared and discussed. © 2010 Springer Science+Business Media B.V.Item Electrodeposition of Zn-Ni, Zn-Fe and Zn-Ni-Fe alloys(2010) Hegde, A.C.; Venkatakrishna, K.; Eliaz, N.Zn-Fe, Zn-Ni and Zn-Ni-Fe coatings were electrodeposited galvanostatically on mild steel from acidic baths (pH 3.5) consisted of ZnCl2, NiCl2, FeCl2, gelatin, sulfanilic (p-aminobenzenesulfonic) acid and ascorbic acid. Cyclic voltammetry showed that the effect of gelatin was more pronounced than that of sulfanilic acid, and that the deposition of the ternary alloy behaved differently from the deposition of the binary alloys. In all three systems, the Faradaic efficiency was higher than 88%, the rate of Zn deposition was heavily influenced by mass-transport limitation at high applied current densities, and the deposition was of anomalous type. For each applied current density, the concentrations of Ni and Fe in the ternary alloy were higher than the corresponding concentrations in the binary alloys. The hardness of Zn-Ni coatings was the highest, while that of Zn-Fe coatings was the lowest. The Zn-Ni-Fe coatings were the smoothest, had distinguished surface morphology, and contained ZnO in the bulk, not just on the surface. The lowest corrosion rate in each alloy system (214, 325 and 26?m year-1 for Zn-Ni, Zn-Fe and Zn-Ni-Fe, respectively) was characteristic of coatings deposited at 30, 30 and 40mAcm-2, respectively. The higher corrosion resistance of the ternary alloy was also reflected by a higher corrosion potential, a higher impedance and a higher slope of the Mott-Schottky line. The enhanced corrosion behavior of the ternary alloy was thus attributed to its chemical composition, phase content, roughness and the synergistic effect of Ni and Fe on the n-type semiconductor surface film. © 2010 Elsevier B.V.Item Corrosion inhibition of 6061 Al-15 vol. pct. SiC(p) composite and its base alloy in a mixture of sulphuric acid and hydrochloric acid by 4-(N,N-dimethyl amino) benzaldehyde thiosemicarbazone(2011) Geetha, G.M.; Nayak, J.; Nityananda Shetty, A.N.The corrosion inhibition characteristics of 4-(N,N-dimethylamino) benzaldehyde thiosemicarbazone (DMABT) on the corrosion behavior of 6061 Al-15 vol. pct. SiC(p) composite and its base alloy were studied at different temperatures in acid mixture medium containing varying concentrations of hydrochloric acid and sulphuric acid using Tafel extrapolation technique and ac impedance spectroscopy (EIS). The effect of inhibitor concentration, temperature and concentration of the acid mixture media on the inhibitor action was investigated. It was found that inhibition efficiencies increase with the increase in inhibitor concentration, but decrease with the increase in temperature and with the increase in concentration of the acid media. Thermodynamic parameters for dissolution process were determined. The adsorption of DMABT on both the composite and base alloy was found to be through physisorption obeying Freundlich adsorption isotherm. © 2010 Elsevier B.V. All rights reserved.Item Development of anti-corrosive multi-layered coatings of zinc-nickel alloy(2011) Subbaiah, Y.; Kaje, V.; Hegde, A.C.Purpose: The purpose of this paper is to develop and optimize anti-corrosive multi-layered coatings of zinc-nickel alloy on carbon steel. Design/methodology/approach: A variety of composition-modulated multi-layer alloy (CMMA) coatings of zinc-nickel were developed on a carbon steel substrate by cyclic changes in cathode current during electrodeposition, coupled with variation of the thicknesses of the individual layers. The corrosion behavior of the coatings was studied in 5 percent NaCl solution by electrochemical methods. Cyclic cathode current densities (CCCDs) and the number of alloy layers were optimized for highest performance of the coatings against corrosion. The factors responsible for improved corrosion resistance were analyzed in terms of change in the intrinsic electrical properties of the capacitance value at the electrical double layer that was associated with micro/nanometric layering. The formation of the semi-conductive surface film, which was responsible for the improved corrosion resistance, was supported by a Mott-Schottky plot and the cyclic polarization study. The formation of multi-layered deposit and the mechanism of corrosion degradation of the coating were analyzed using scanning electron microscopy. Findings: CMMA coatings with an optimal configuration of (Zn-Ni)2.0/4.0/300 showed ~35 times better corrosion resistance compared to a monolithic (Zn-Ni)3.0 alloy coating of the same thickness. The peak performance was attributed to the change in intrinsic electrical properties of the coating and this conclusion was supported by dielectric spectroscopy. Originality/value: The paper describes the optimization of CCCD and the number of deposited layers by development of electrolytic deposition of anti-corrosive multi-layered zinc-nickel coatings from a single plating technique. © Emerald Group Publishing Limited.Item Development of nano-structured cyclic multilayer Zn-Ni alloy coatings using triangular current pulses(2011) Bhat, R.S.; Hegde, A.C.Cyclic multilayer alloy (CMA) deposits of Zn-Ni were developed on mild steel from sulphate bath having thiamine hydrochloride (THC) and citric acid (CA) as additives. CMA coatings were developed galvanostatically using triangular current pulses, under different conditions of cyclic cathode current density (CCCD's) and number of layers. The corrosion behaviors of the coatings were evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy methods, and were compared with that of monolayer Zn-Ni alloy of same thickness. At optimal configuration, CMA coating represented as, (Zn-Ni)2.0/5.0/300 was found to exhibit ?40 times better corrosion resistance compared to monolayer alloy, (Zn-Ni)3.0. Cyclic voltammetry study demonstrated that THC and CA have improved the appearance of the deposit by complexation with metal ions. The corrosion protection efficacy of CMA coatings was attributed to the difference in phase structure of the alloy in successive layers, evidenced by XRD analysis. The formation of multilayer and corrosion mechanism was analyzed by Scanning Electron Microscopy (SEM) study. © 2011 Allerton Press, Inc.Item Effect of heat treatment on pitting corrosion resistance of 6061 Al/SiCP composite coated by the cerium oxide film in 3.5 N NaCl solution(2011) Rajasekaran, S.; Udayashankar, N.K.; Nayak, J.One of the main drawbacks of 6061 Al/SiCP composite is its poor pitting corrosion resistance in the aggressive environment containing chloride ions, such as seawater, for example. The present article deals with the investigations of effects of aging on the corrosion behavior of 6061 Al/SiCP composite and of the heat treatment on the pitting corrosion resistance of 6061 Al/SiCP composite coated by cerium oxide prepared by chemical bath technique. Potentiodynamic polarization test was used to study the corrosion behavior of cerium oxide coatings in 3. 5N NaCl solution. The microstructure of cerium oxide was examined by scanning electron microscopy (SEM) and the formed phases were identified by X-ray diffraction (XRD). The pitting corrosion resistance of the cerium oxide coating was found to be improved after heat treatment at 300°C for 30 min. © 2011 Allerton Press, Inc.Item The corrosion inhibition of maraging steel under weld aged condition by 1(2E)-1-(4-Aminophenyl)-3-(2-Thienyl)prop-2-en-1-one in 1.5 M hydrochloric acid medium(Springer New York LLC barbara.b.bertram@gsk.com, 2012) Sanatkumar, B.S.; Nayak, J.; Nityananda Shetty, A.N.The influence of 1(2E)-1-(4-Aminophenyl)- 3-(2-Thienyl)prop-2-en-1-one (ATPI) on the corrosion behavior of weld aged maraging steel in 1.5 M hydrochloric acid was studied by potentiodynamic polarization method and AC impedance (EIS) technique at different temperatures. The results showed that the inhibition efficiency of ATPI increased with the increase in the concentration of inhibitor and decreased with the increase in temperature. ATPI acts as a mixed type inhibitor without affecting the mechanism of the hydrogen evolution reaction or iron dissolution. The adsorption of ATPI on a weld aged maraging steel surface obeys the Langmuir adsorption isotherm equation. Both activation and thermodynamic parameters were calculated and discussed. ATPI inhibits the corrosion through both physisorption and chemisorption on the alloy surface. The surface morphology of the weld aged maraging steel specimens in the presence and the absence of the inhibitors was studied by the respective SEM images. © ACA and OCCA 2011.