Development of Al2O3, ZrO2 and Al2O3/ ZrO2 thin film coating on mild steel using RF sputtering to improve corrosion protection for small scale industrial applications.

Author

G. ABHISHEK, Dr. KALAPALA PRASAD, THANETI LILLY RANI, P. SRINIVASA SUBBA RAO

Abstract

 Mild steel is commonly used in engineering and manufacturing industries because it is inexpensive, easily available, and has good mechanical properties. However, it is highly susceptible to corrosion, particularly in industrial environments. Applying protective thin-film coatings to the steel surface is an effective method to improve its corrosion resistance. In this study, Al₂O₃, ZrO₂, and Al₂O₃–ZrO₂ (AZO) composite coatings were deposited on mild steel using radio-frequency (RF) sputtering. The coatings were deposited at a pressure of 2 × 10⁻² mbar with an RF power of 70 W. X-ray Photoelectron Spectroscopy (XPS) confirmed the presence of aluminium and zirconium in the deposited coatings. X-ray Diffraction (XRD) and Raman spectroscopy were used to study the structural and bonding characteristics of the coatings. Raman analysis showed peaks in the 300–530 cm⁻¹ range for Al₂O₃ and AZO, with a major peak around 670 cm⁻¹ observed for the studied coatings. Field Emission Scanning Electron Microscopy (FESEM) showed a dense coating with a thickness of approximately 200 ± 20 nm. Atomic Force Microscopy (AFM) measured peak heights of 226 nm, 300 nm, and 104 nm for Al₂O₃, ZrO₂, and AZO coatings, respectively. The corrosion performance was investigated using Open Circuit Potential (OCP), Electrochemical Impedance Spectroscopy (EIS), and Potentiodynamic Polarization techniques. The results showed that the AZO composite coating provided better corrosion protection than the individual Al₂O₃ and ZrO₂ coatings. The improved corrosion resistance is associated with the dense protective coating, which reduces the contact between the mild steel surface and the corrosive environment.

Keywords

Al2O3; ZrO2; Al2O3/ ZrO2 composite; Mild steel; RF Sputtering; Thin film coating; Corrosion resistance; Electrochemical corrosion.

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References

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