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In this study, Zn–Ni–Cu and Zn–Ni–Cu–TiB 2  coatings were deposited using high-velocity oxy-fuel (HVOF) thermal spray technique on a mild steel substrate. Corrosion tests like neutral salt spray (NSS) following (ASTM B-117) standard and immersion cycle test following ASTM G-31, ASTM G1-03, standards were carried out for Zn–Ni–Cu and Zn–Ni–Cu–TiB 2  coated mild steel along with uncoated mild steel acting as a control. Both Zn–Ni–Cu and Zn–Ni–Cu–TiB 2  coated mild steel were corrosion resistant as compared to uncoated mild steel. Raman analysis following the immersion cycle test inferred that uncoated mild steel had all forms of rust. While Zn–Ni–Cu and Zn–Ni–Cu–TiB 2  coated mild steel developed very little rust. The characterization helped to understand the changes in the surface before and after tests. It was observed that both Zn–Ni–Cu and Zn–Ni–Cu–TiB 2  coated mild steel had little corrosion degradation of surface as compared to uncoated mild steel. Suggesting that both coatings performed significantly better compared to uncoated mild steel in corrosive environments. Polarization and EIS tests of both coated and uncoated mild steel in a 3.5% NaCl medium helped to understand the behaviour of coatings over a range of frequencies. Both coated samples had high polarization potential  E  corr  values and lower polarization current  I  corr  values as compared to uncoated mild steel. Inferring better performance of coatings in corrosive environments as compared to uncoated mild steel.

Corrosion behaviour OF HVOF deposited Zn–Ni–Cu and Zn–Ni–Cu–TiB 2 coatings on mild steel