Sealing of Hard Chrome Plating

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1 Sealing of Hard Chrome Plating Background Hard chrome coating is used to protect steel components from corrosion in salt and acid medium. It is extensively applied on steel cylinders, gears, used in many applications. The hard chrome coatings not only enhance the corrosion resistance but the hardness and wear resistance as well. Defects in the hard chrome coatings such as micro- cracks alert the performance of the coatings. When exposed to corrosive environment, the cracks are enlarged due to the penetration of corrosive molecules under the chrome layer. Coating failure may happen due to stress corrosion cracking. Figure 1 shows the cracks on the surface layer of the coating and cross- section. The cracks are propagated inside the layer depth. The width of cracks ranges from less than micron to more than few microns.

2 Figure 1: Micro- cracks of hard chrome plating Aim of the project Using nano- ceramic sealant to seal the cracks in hard chrome layer Measure the depth of penetration of the sealant into the cracks Measure the corrosion resistance before and after applying the sealant Core Activities Hard Chrome Plating: 12 mild steel specimens (70x20x5 mm) were chrome plated at Callcott & Downey Engineering Services (David Gilbert: 8 Bell Street, Kewdale WA 6105 Phone: (08) ). Nano- ceramic sealant: The ceramic sealant was applied on few samples Microscopic observation: Optical and SEM microscopic observation to the surface and cross- sectioned samples to investigate the presence of the nano- ceramic inside the cracks, as well as the level of penetration of the sealant through the cracks. Corrosion Test: Using salt spray and droplet test to measure the corrosion resistance of the hard chrome before and after sealing in 3.5% NaCl. Supporting Activity: Corrosion in 3.5% NaCl Hard chrome samples (1- sealed and 2- unsealed) were immersed in 3.5% NaCl solution. The solution was changed everyday with a fresh one. The samples and solution was stored in glass container with a lid to prevent the solution evaporation. We kept the oxygen level constant in the salt solution by release the lid of the container for 30 min every day. Before Corrosion Test After 3 days in 3.5% NaCl solution

3 Hanna NanoCeramic Magdi Hanna, PhD M Unsealed Sealed Fig 2 A: Before and after 3 days immersion in 3.5% NaCl Sealed Fig 2 B: After 22days in 3.5% NaCl Unsealed SEM Characterization

4 Unsealed Sealed Fig 3: SEM images of hard chrome surface before (left) and after (right) sealing Electrochemical Corrosion Test Experiment set up For electrochemical measurements, both the unsealed and sealed chrome plating samples were fixed in a perspex electrochemical cell with an exposed area of 3.14 cm 2. The electrochemical cell assembly consisted of working electrode (sealed and unsealed samples), saturated calomel electrode (SCE) as the reference electrode, and a Pt mesh used as counter electrode. Electrochemical measurements were performed using a Solartron potentiostat/galvanostat- model 1280B unit. The potentiodynamic polarization curves were obtained at mv/s in the potential range Eop ± mv. The Tafel extrapolate method was adopted to acquire the values of the corrosion current (Icorr).

5 Fig 4: OCP and polarization curves of unsealed and sealed hard chrome samples in 3.5% NaCl Figure 4 shows the open circuit potential (OCP) and potentiodynamic polarization curves of unsealed and sealed hard Cr coating on mild steel in 3.5% NaCl. The open circuit potential of the sealed sample showed more positive shift of the potential at open circuit mode ( 430 mv) than unsealed sample (E o p = 560 mv). The potentiodynamic polarization curves of the sealed sample showed a positive shift of the potential from 560 to 508 mv for the sealed sample. Electrochemical corrosion parameters, i.e. corrosion potential (E corr ), and corrosion current density (i corr ) obtained from the Tafel extrapolation of the polarization curves, were given in Table 2, Sample E corr (mv vs SCE) I corr (µa) βa mv/decade βc mv/decade R p (KΩ) Unsealed Sealed

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