Development of compositionally modulated multilayer Zn–Ni deposits as replacement for cadmium

Compositionally modulated multilayer (CMM) Zn–Ni deposits were electrodeposited from single acidic bath (pH = 4.7) by using a potentiostatic sequence. The Zn and Ni composition in the alloy was tailored as a function of distance from the steel substrate. X-ray diffraction studies of the deposit showed the presence of γ-phase with a composition of Ni5Zn21. The corrosion properties of modulated multilayer coatings were studied in 5% NaCl solution using electrochemical corrosion techniques. The polarization resistance of the deposits varied as a function of Ni content between 1700 and 3440 Ω. CMM Zn–Ni with 20 wt% Ni exposed in ASTM B117 salt spray test did not show any red rust formation after 400 h.