Analysis of the Properties of Anticorrosion Systems Used for Structural Component Protection in Truck Trailers
<p>Steel guide appearance with the applied bolt connection (the location where samples were taken for testing is marked with a white arrow).</p> "> Figure 2
<p>Microstructure observed on the cross-section of the tested coatings using a scanning microscope: (<b>a</b>)—thermo-diffusion zinc coating, (<b>b</b>,<b>d</b>)—hot-dip zinc coating, (<b>c</b>)—EDS analysis of thermo-diffusion coating’s cross section according to the green line, (<b>e</b>)—cataphoretic coating.</p> "> Figure 2 Cont.
<p>Microstructure observed on the cross-section of the tested coatings using a scanning microscope: (<b>a</b>)—thermo-diffusion zinc coating, (<b>b</b>,<b>d</b>)—hot-dip zinc coating, (<b>c</b>)—EDS analysis of thermo-diffusion coating’s cross section according to the green line, (<b>e</b>)—cataphoretic coating.</p> "> Figure 3
<p>Change in hardness measured on the cross-section of the tested coatings.</p> "> Figure 4
<p>Comparison of the roughness of the tested coatings.</p> "> Figure 5
<p>An example of a roughness profile (<b>a</b>) and surface topography of a hot-dip zinc coating (<b>b</b>).</p> "> Figure 6
<p>The course of changes in the friction coefficient value during a single measurement.</p> "> Figure 7
<p>Comparison of the average friction coefficient values determined for the tested coatings.</p> "> Figure 8
<p>The cross-section microstructure of the coating after tribological tests: (<b>a</b>)—hot-dip coating, (<b>b</b>)—thermo-diffusion coating, (<b>c</b>)—cataphoretic coating.</p> "> Figure 9
<p>Sample surface after tribological test: (<b>a</b>)—hot-dip coating, (<b>b</b>)—thermodiffusion coating, (<b>c</b>)—cataphoretic coating.</p> "> Figure 10
<p>Tested elements after the corrosion test: (<b>a</b>)—guide; (<b>b</b>)—M12 × 40 bolts.</p> ">
Abstract
:1. Introduction
2. Materials and Methods
- Surface roughness was measured using the Phase View system (PhaseView, Verrières-le-Buisson, France) with ZeeScan software version 2.4, employing a non-contact microscopic attachment method;
- The chemical composition analysis was conducted using: carbon and sulfur analyzer LECO CS844 (LECO Corporation, St. Joseph, MI, USA), mass spectrometer by: Thermo Fisher Scientific (iCAP Q, Waltham, MA, USA);
- The phase analysis using SEM was performed on the JEOL JSM-7800F scanning electron microscope. (JEOL Ltd. Akishima, Tokyo, Japan);
- Coating thickness was assessed using a PosiTector 6000MP magnetic induction tester with a 90° depth finder (DeFelsko, New York, NY, USA);
- Hardness measurements were measured at the cross-section of the tested coatings and the subsurface layer of steel using a Vickers hardness tester (HV 0.02) with a Mitutoyo Micro-Vickers HM-210 A device (Model 810–401 D, Mitutoyo, Kawasaki, Japan);
- Coating corrosion resistance was evaluated using an Ascott CC2000 salt chamber (Ascott, Staffordshire, UK) according to the PN-EN ISO 9227:2017-06 standard [54]. The tests utilized a corrosive medium of NaCl at a concentration of 50 g/dm3, with a solution density of 1.035 g/cm3 and a fall value of 1.033 g/cm3, pH 6.7, air pressure of 1 bar, and a chamber temperature of 40 °C. Post-testing, the samples were cleaned in a 15% hydrochloric acid (HCl) solution containing 1% corrosion inhibitor PICKLANE 60 (COVENTYA, Weiland, Germany).
- Tribological properties tests were carried out using the T-11 tester produced by ITEE, Radom, Poland.
3. Results and Discussion
3.1. Microscopic Observations
- cutting and preliminary shaping of the samples;
- hot mounting;
- grinding using water-resistant papers of various grit sizes,
- polishing with diamond suspensions.
3.2. Hardness and Roughness Tests
3.3. Friction Coefficient Measurement
3.4. Corrosion Resistance Test
4. Conclusions
- The research conducted indicates that the type of applied zinc coating should be closely dependent on the operating conditions. In cases where a more aggressive corrosive environment is present, the best results are achieved with a hot-dip galvanized coating. In conditions of higher exposure to abrasive wear, better results are obtained with a thermo-diffusion zinc coating. A paint coating is generally sufficient for moderate exposure to corrosion and abrasive wear, especially where aesthetic considerations are key.
- The differentiation of the microstructure of the tested coatings has a direct impact on the measured characteristics of the friction coefficient changes and the average value of this parameter. The highest friction coefficient value was determined for the hot-dip zinc coating μHD = 0.4, a slightly lower value was measured for the thermo-diffusion coating μT = 0.3, and the lowest for the cataphoretic coating—μC = 0.19. When selecting a protective coating for a bolts connection, the self-locking of the thread should also be taken into consideration, which can vary widely depending on the kind of coating used.
- During the tribological test, the greatest wear was observed in the case of the cataphoretic coating, where the depth of the worn groove was equal to the total thickness of the coating (35 μm). In the case of the thermo-diffusion coating, the greatest abrasion resistance was achieved—the groove depth was only 5 μm, while the zinc hot-dip coating was worn to a depth of 25 μm.
- In terms of measured corrosion resistance, the most effective protection for automotive components is provided by a hot-dip zinc coating. This coating significantly outperforms other protective coatings in terms of durability. The corrosion resistance of hot-dip zinc, as quantified by the duration until the onset of red corrosion, is more than ten times greater than that of alternative coatings. This remarkable performance is attributed to the zinc’s ability to form a robust, sacrificial layer that effectively shields the underlying metal from environmental factors such as moisture, salts, and oxygen. As a result, components coated with hot-dip zinc experience a much slower degradation process, leading to extended service life and reduced maintenance costs. This makes it an ideal choice for automotive applications, where long-term durability and reliability are crucial.
- Future research on the discussed coatings should focus on evaluating their performance under varied environmental conditions, including: UV radiation, cyclic humidity, temperature fluctuations, and exposure to industrial pollutants. Further studies could also investigate the long-term durability and adhesion of the coatings under mechanical stress and repeated loading.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
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Chemical Composition of Steel, %. | ||||||||
---|---|---|---|---|---|---|---|---|
C | Si | Mn | P | S | Cr | Cu | Ni | |
23MnB4 (1.5535) | 0.2 | 0.1 | 1.1 | 0.02 | 0.02 | 0.3 | 0.2 | 0.005 |
C | Si | Mn | P | S | Al | Nb | V | |
S355MC (1.0976) | 0.1 | 0.01 | 1.0 | 0.02 | 0.01 | 0.005 | 0.05 | 0.1 |
Sample No. | Kind of Coating | Sample Preparation Methodology |
---|---|---|
1 | Cataphoretic painting according to PN-EN ISO 12944-2:2018-02 [38] | The samples were subjected to etching in a 15% hydrochloric acid (HCl) solution, followed by immersion in CathoGuard 900, a water-soluble coating produced by BASF Coating AG, Münster, Germany (pH range: 5.5–7.0; voltage: 220–250 V; deposition rate 10–12 μm/min; duration: 250 s). The coated samples were then dried for 1 h at a temperature of 200 °C. |
2 | Hot-dip galvanized according to PN-EN ISO 10684:2006 [52] | Samples were etched in a 15% hydrochloric acid (HCl) solution, fluxed, and hot-dip galvanized at 480 °C in a zinc (Zn) bath with aluminum (Al 0.1%), bismuth (Bi 0.05%), and nickel (Ni 0.05%) additives, duration: 240 s, followed by water cooling. |
3 | Thermo-diffusion according to PN-EN ISO 17668 [53] | Samples were etched in a 15% hydrochloric acid (HCl) solution, followed by galvanization in a powder with filler and activator in a rotary chamber at 10–20 rpm, 425 °C for 5 h, and then cooled in air to 22 °C. |
No. of Measurements and the Thickness of the Coating, µm. | |||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | Average (s.d) | |
Hot-dip galvanized | 40 MIN | 43 | 43 | 47 MAX | 45 | 45 | 44 | 45 | 47 | 46 | 44.5 (2.1) |
Thermo-diffusion | 55 MAX | 52 | 53 | 51 | 53 | 50 MIN | 54 | 54 | 51 | 52 | 52.5 (1.7) |
Cataphoretic painting | 31 MIN | 35 MAX | 32 | 35 | 33 | 34 | 31 | 35 | 34 | 32 | 33.2 (1.6) |
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Skotnicki, W.; Jędrzejczyk, D. Analysis of the Properties of Anticorrosion Systems Used for Structural Component Protection in Truck Trailers. Materials 2024, 17, 6303. https://doi.org/10.3390/ma17246303
Skotnicki W, Jędrzejczyk D. Analysis of the Properties of Anticorrosion Systems Used for Structural Component Protection in Truck Trailers. Materials. 2024; 17(24):6303. https://doi.org/10.3390/ma17246303
Chicago/Turabian StyleSkotnicki, Wojciech, and Dariusz Jędrzejczyk. 2024. "Analysis of the Properties of Anticorrosion Systems Used for Structural Component Protection in Truck Trailers" Materials 17, no. 24: 6303. https://doi.org/10.3390/ma17246303
APA StyleSkotnicki, W., & Jędrzejczyk, D. (2024). Analysis of the Properties of Anticorrosion Systems Used for Structural Component Protection in Truck Trailers. Materials, 17(24), 6303. https://doi.org/10.3390/ma17246303