Corrosion Resistance of Electrodeposited Zn-Fe-Cr Coatings on Sintered Nd-Fe-B

Zn-Fe-Cr coatings were successfully deposited on sintered Nd-Fe-B matrix through the addition of the complexing agent etidronic acid (HEDP) to the plating solution; the electrodeposited process of the metal elements and the corrosion behavior of the coatings were also investigated. Through cyclic voltammetry (CV) tests, it was observed that the reduction potential difference between the metal elements was reduced by the addition of HEDP, which contributed to a more feasible electrodeposited process. The surface of Zn-Fe-Cr coating was covered by a chromate conversion film, and its microstructure was identified as the solid solution of Fe and Cr in Zn matrix. Compared with Zn and Zn-Fe coatings, the corrosion current density (Jcorr) of Zn-Fe-Cr coating was decreased to 0.28 × 10−6 A·cm−2, and the corrosion potential (Ecorr) was increased to −1.01 V. Compared with the Zn and Zn-Fe coatings, the corrosion rate of the Zn-Fe-Cr coating has decreased by 90% and 98%, respectively. The corrosion resistance of coatings was further analyzed by neutral salt spray tests (NSS), and the analysis results showed that a composite oxide layer, composed of ZnO and Cr2O3, was formed in the corroded area of Zn-Fe-Cr coating during the corrosion process, which is capable of effectively inhibiting the expansion of the corrosion area. This research provides a promising strategy for ensuring the long-term service integrity of sintered Nd-Fe-B materials in marine environments.