A magnetic field based strategy for designing durable Zn–Ni alloy coatings on mild steel for corrosion resistant applications

This study investigates the application of the magnetohydrodynamic (MHD) effect to improve the corrosion resistance of Zn–Ni alloy coatings via controlled electrodeposition. The application of a magnetic field transformed the deposition mechanism from anomalous to normal, resulting in a substantial increase in nickel content from 7.95 wt% under standard conditions to 80.93 wt% with magnetic assistance. The perpendicular orientation of the magnetic field relative to ion flow maximized the Lorentz force, significantly improving mass transport during deposition. Among the various magnetic field intensities studied, the coating deposited at 0.3 T demonstrated the highest corrosion resistance, outperforming both other field conditions and the coating obtained at a conventional current density of 3.0 A dm−2. This work is significant as it presents a novel and efficient strategy to tailor alloy composition and enhance the protective properties of Zn–Ni coatings. The findings provide valuable insights into magnetoelectrodeposition as a potential technique for producing high-performance, corrosion-resistant coatings for industrial applications.