Characterization and corrosion analysis of zinc coating by electrodeposition using acid chloride electrolyte solution

This study originally optimized the electrodeposition of zinc onto brass sheets and mild steel wire from an acid chloride electrolyte bath, employing a systematic trapezoidal Hull cell technique. Unlike traditional approaches, this research meticulously investigated the synergistic effects of bath composition, pH, voltage, temperature, plating time, and surfactant presence to achieve superior coating properties. Novel optimization strategies, including a refined trial method using the Hull cell, yielded precise control over electrolyte conditions. Zinc coating thickness trends were rigorously evaluated with an elcometer, correlating variations in current and time to coating uniformity. Advanced characterization techniques, such as scanning electron microscopy (SEM), revealed detailed grain size and surfactant distribution, while nano-indentation testing quantified the nano-hardness of the deposited zinc. Furthermore, the study uniquely assessed corrosion resistance and degradation through prolonged salt spray testing (ASTM B117), providing critical insights into the long-term performance of these optimized zinc coatings. • Hull cell study revealed effects of basic constituents on zinc coating quality. • Zinc coating thickness increased with higher current density. • Surfactants improved coating uniformity in SEM analysis. • Thicker zinc coatings showed enhanced corrosion resistance. • Hull cell method optimized electroplating bath composition.