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Electrodeposition and characterization of novel ceria-doped Zn-Co composite coatings was the main goal of this research. Electrodeposited composite coatings were compared to pure Zn-Co coatings obtained under the same conditions. The effect of two ceria sources, powder and home-made sol, on the morphology and corrosion resistance of the composite coatings was determined. During the electrodeposition process the plating solution was successfully agitated in an ultrasound bath. The source of the particles was found to influence the stability and dispersity of plating solutions. The application of ceria sol resulted in an increase of the ceria content in the resulting coating and favored the refinement from cauliflower-like morphology (Zn-Co) to uniform and compact coral-like structure (Zn-Co-CeO2 sol). The corrosion resistance of the composite coatings was enhanced compared to bare Zn-Co as evidenced by electrochemical impedance spectroscopy and scanning Kelvin probe results. Zn-Co doped with ceria particles originating from ceria sol exhibited superior corrosion resistance compared to Zn-Co-CeO2 (powder) coatings. The self-healing rate of artificial defect was calculated based on measured Volta potential difference for which Zn-Co-CeO2 (sol) coatings exhibited a self-healing rate of 73.28% in a chloride-rich environment.

Zn-Co-CeO2 vs. Zn-Co Coatings: Effect of CeO2 Sol in the Enhancement of the Corrosion Performance of Electrodeposited Composite Coatings