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Anti-corrosion sustainability of Anodized, Electrolytic Deposition and Powder

Coating Layer on ADC-12 Alloy

Conference Paper · November 2023

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 Proceedings of the
7th International Conference on Mechanical Engineering and Renewable Energy 2023
(ICMERE 2023) 16 – 18 November 2023, Chattogram, Bangladesh

ICMERE 2023-PI-036

Anti-corrosion sustainability of Anodized, Electrolytic Deposition and Powder Coating

Layer on ADC-12 Alloy
Surovi Aktar Nupur1, Anisul Islam Suva2, Md. Tarek Mahmud Patwary 3 and Dr. Md. Tazul Islam4

Department of Mechanical Engineering, Chittagong University of Engineering and Technology, Bangladesh.

suroviaktarnupur984@gmail.com1, anisulislam.me@cuet.ac.bd2, tareqmp@gmail.com3,
tazul2003@yahoo.com4

Abstract- The coating is done for protecting metal from deterioration. Coating sustainability, thickness,
and adhesive property vary with coating types. In this paper, the sustainability of different coatings on
aluminum alloy has been compared. Three types of coatings on ADC-12 aluminum alloy are being studied.
Anti-corrosion sustainability of Anodized, Electrolytic Deposition, and Powder coated ADC-12 samples
has been analyzed through the Detergent test, Salt Spray Test (SST) where aggressive environments have
been created. Detergent Test and Salt Spray Test (SST) have conducted for 192 hours and 168 hours
respectively. Adhesion of coating layer is experimented by Adhesion Tape Test. The thickness of coating
layer is also measured in this research as it is an important phenomenon to compare among different
coatings. Analyzing the results, it has been observed that Powder coating on ADC-12 has more corrosion
resistance and thus, has more sustainability against corrosion. The coating materials are determined and,
the base metal compositions are also verified by X-ray fluorescence spectroscopy process (XRF). For
effective application of metallic coatings and for the study to make the coatings more anti-corrosive, it is
necessary to analyze the durability of various types of coating against corrosion.

Keywords: Coatings, ADC-12, Salt Spray Test, Corrosion Resistance

1. INTRODUCTION methods such as Anodizing, Electrolytic Deposition and

We can‟t imagine our technology and modern life
without the applications of metal. Long-time uses of
metal cause corrosion and damage in the metal surface
caused by its chemical changes and that metallic part
needs to be replaced which is costly, time worthy and
sometimes risky. The coating is the process of providing
a thin corrosion-resisting layer in a metal surface to
prevent corrosion and give the metal a longer life and it
obviously reduces cost and time rather than replacing it.
The coating is also helpful for our environment as it
resists corrosion and thus, reduces pollution.
Aluminum alloy is one of the most used metals for
its many useful characteristics such as lightweight,
easily can be machined and cast, non-magnetic, good
heat and electrical conductor, non-sparking. For
improving the corrosive behavior, the alloy of
aluminum is coated with various coating materials[1].
ADC-12 is the alloy of aluminum which is 4000
series of aluminum alloy and contains about 84%
aluminum, 11% silicon and some other metals such as
Fe, Cu, Mn, Mg, and Zn and is commonly used in die-
casting. ADC-12 works well at high or low pressures
and is simple to cast[2]. This alloy is cost-efficient,
manufacturing friendly and applicable for cylinder head
covers, cylinder blocks, brackets, sensors, refrigerators,
washing machine parts, motor housing etc. ADC-12 can
be coated with various coating materials and coating
Powder coating. ADC-12 with different coating
materials and coated by different methods has varieties
in its corrosion resistivity against metal deterioration.
Analyzing the sustainability of different types of coating
against corrosion is requisite for proper applications of
metallic coatings and for the study to make the coatings
more anti-corrosive.
Among numerous exploration techniques of anti-
corrosion properties, Salt Spray Testing, Coating
Adherence testing, coating layer behavior against the
Detergent solution, zincating treatments[3], adding
different solid lubricant fillers[4], and examination with
UV exposure[5] are remarkable.
In a 3.5 percent sodium chloride solution, the
corrosion behavior of the hard anodizing coating layer
formed on Al2014, Al6061, and Al7075 aluminum
alloys in sulphuric acid electrolyte containing sodium
lignin sulphonate was investigated using salt spray
procedure and potentiodynamic polarization technique.
The hardness order of anodized Aluminum alloys is
Al7075 > Al2014 > Al6061, according to the results.
Aluminum alloys have the following abrasion
resistance: Al2014 > Al7075 > Al6061, while anodized
Aluminum alloys have the following abrasion
resistance: Al7075 > Al6061 > Al2014[6].
The Electrodeposition method has remarkable
benefits because it prevents subsequent surface
© ICMERE 2023
modification and improves coating stability. The
hydrophobicity and anti-corrosion performance of
coatings created by the electrodeposition technique can
be strongly influenced by crystallization modifiers,
current density, and deposition time[7].
The corrosion resistance of anodized, sol–gel coated,
and anodized plus sol–gel duplex coated AA 3004 was
investigated and compared to that of hydrothermally
sealed anodized AA 3004. While compared to
hydrothermal sealing, sol–gel coating was proved to be
a better sealant for the anodized layer, as evidenced by
the greater corrosion resistance of anodized plus duplex
coatings when compared to the separate layers[8].
For industrial applications coated ADC-12 aluminum
alloy has been used and which type of coating is more
anti-corrosive has been studied in this paper through the
detergent test, salt spray test, the adhesion tape test. The
thickness of coating layer is also a very important
phenomenon that has been measured and compared.
This paper is organized in this pattern: section 2
studies Anodized, Electrolytic Deposition and Powder
coating, section 3 makes identification of coating and
base metal components, section 4 describes the
methodology, section 5 addresses the result and analysis
and section 6 finally terminates the paper.
anodizing, titanium can also be anodized. While
aluminum is anodized traditionally, direct electrical
current (DC) is conducted through a bath of sulfuric
acid, which serves as the electrolyte, with the treated
aluminum acting as the anode. A transparent film of
aluminum oxide forms on the aluminum's surface as a
result of this process. A combination of oxides,
phosphates, and chromates make up the so-called zinc
anodized surface. Alternating current is being used in
the zinc anodizing process rather than direct current,
while most but not all aluminum anodizing methods
employ direct current[9].
Fig. 2 represents the anodizing coating method
where aluminum is used as an anode and aluminum
oxide forms the surface which is submerged in the
electrolyte and thus, makes an anti-corrosive layer and
protects the metal.

2. RIVEW OF COATING METHODS

The coating on metals can be done by various
processes, e.g. Chemical Vapor Deposition Coating
(CVD), Physical Vapor Deposition Coating (PVC),
Micro-Arc Oxidation (MAO) Coating, Sol-gel,
Anodizing, Electrodeposition, Powder Coating etc.
Different coatings are based on different criteria related
to the base metal, coating layer components, and Fig. 2: Anodizing Coating Process
different industrial applications.
2.2 Electrolytic Deposition Coating
It is an electrochemical method (ELD) that forms a
dense metallic coating on conductive substrates with a
homogeneous thickness distribution. While inside an
electrochemical unit cell, substrate and deposition
materials are selected as cathode and anode. Metallic
ions travel toward the working electrolyte and then
toward the substrate when a potential difference
between the anode and cathode poles is applied. Super-
saturation of the electrolyte is required for the
deposition phase, which happens due to the charging
current in the circuit. The metallic ions concentration in
the electrolyte stays unchanged in this approach[10].

Fig. 1: Different types of coating methods

Electrolytic Deposition (ELD) and Electrophoretic

Deposition (EPD) are the varieties of Electrodeposition
coating. Anodizing, Electrolytic Deposition (ELD), and
Powder Coating (PC) are mostly applied on aluminum
alloy, specifically on ADC-12 and these three types
coatings are described in this section.

2.1 Anodizing
Anodizing is the electrochemical process where a base
metallic oxide layer is formed to protect the metal from Fig. 3: Electrolytic Deposition Coating Process
deterioration. Aluminum alloys are suitable for
© ICMERE 2023
 Above figure is Fig. 3, has shown the electrolytic Chemical Anodized Electrolytic Powder
deposition coating method where base alloy aluminum Compositions Coated layer Deposition Coated
(wt. %) Coated layer layer
is used as the cathode, and a layer of the anodic metal is
created in the cathode surface.
Si 43.64 5.48 1.73
2.3 Powder Coating Zn 8.80 41.78 1.77
The theory behind powder coating is that items with Ti 0.26 <LOD 67.53
opposite electric charges (positive and negative) attract Al 36.83 0.89 2.31
each other. Passing powder particles through a particular Ag 0.05 0.58 0.10
spraying gun makes them negatively charged. An Cu 4.88 23.11 0.68
electric field forms between the spray gun and the Cr 0.06 <LOD 3.99
earthed component as a result of this. The powder is Co <LOD 0.14 0.05
applied to a prepared substrate's surface, melted, and Cd 0.02 <LOD 0.03
then dried and solidified into a protective/decorative V 0 <LOD 17.73
coating during the process. Surface preparation, coating Fe 3.24 8.27 0.51
application, and heat curing are the three processes. Te 0.01 <LOD 0.07
Thermal coating provides the perfect base for powder Mn 0.68 0.83 2.16
coating[11]. Bi 0.03 0.28 0.05
Ni 0.18 0.51 0.05
W 0.07 0.26 0.05
Zr 0.04 4.79 0.29
Nb <LOD <LOD 0.004
Pb 0.88 0.97 0.41
Pd 0.03 0.31 0.05
Ru <LOD 0.03 0.004
Sn 0.28 2.75 0.38
Fig. 4: Powder Coating Process Sb 0.04 <LOD 0.07

Powder coating gun creates charged powder cloud

and thus, a charged electric field between the path of the
gun and the workpiece showing in Fig. 4.
3. IDENTIFICATION OF COATING AND BASE
METAL COMPONENTS
The base is ADC-12 alloy and three types of coatings
are on it. It is necessary to verify the samples we have
collected whether it is exact ADC-12 or not and the
percentage of metals. Metals consisting in the coating
layers are also specified by X-ray fluorescence
spectroscopy (XRF).
3.1 Coating layer Components
X-ray fluorescence spectroscopy (XRF) device
allows to identification of the elements of metals. In our
work, elements of anodized, electrodeposition, and
powder coating layer have been determined.
From these XRF results, it has been obtained that
anodized layer is Si, Al based, Electrolytic layer is Zn,
Cu based and Powder Coated layer is Ti, V based.
Percentages highlighted with bright green colors in table
1 are representing the major components of Anodized,
Electrolytic deposition coated and Powder coated layer
and LOD means Limit of Detection.
3.2 ADC-12 Compositions Verification
The base metal elements compositions found from
XRF are 84.62% Al, 11.34% Si and others. The
composition percentages are such that the alloy grade is
close to ADC-12 and it is verified that the base metal is
ADC-12 according to the sample supplier.
Table 2: Components of ADC-12 alloy
Grade
Chemical composition (wt. %) close
to

The anodized layer has 43.64% Si, 36.83% Al, 8.8%

Zn, 4.89% Cu and other elements with small percentages, Al Si Zn Cu Mn Mg Fe
i.e., Fe, Ag, Bi, Cd, Cr, Mn, Pb, Ni, Pd, Sn, Sb, Te, Ti, ADC-12
W and Zr. 84.62 11.34 1.76 1.04 0.15 0.15 0.93
The electrolytic coating layer has 41.78% Zn,
23.11% Cu, 8.27% Fe, 5.48% Si and other elements with
small percentages, i.e., Al, Ag, Bi, Co, Mn, Pb, Ni, Pd, The component percentages of ADC-12 base metal
Ru, Sn, W and Zr. have been shown in the above table.

The powder coating layer has 67.53% Ti, 17.73% V,

3.99% Cr, 2.31% Al and other elements with small
percentages, i.e., Ag, Bi, Co, Cd, Cu, Fe, Mn, Nb, Pb, Ni,
Pd, Ru, Sn, Sb, Si, Te, Ti, V, Zn, W and Zr.
A table representing the components has been shown.
Table 1: Components of coating layers
4. METHODOLOGY
For the experiment of identifying the sustainability
or corrosion-resisting property of three types of the
coating layer on ADC-12 aluminum alloy, corrosive
environments have been applied on the samples by
performing Adhesion Tape Test, detergent Test, and Salt
© ICMERE 2023
Spray Test.
4.1 Adhesion Tape Test
The tape test has conducted at room temperature. An
area free of blemishes and minor surface imperfections
has been selected and placed on a firm base. Cutting
five single lines each 25 mm long and 1 mm apart
through the film to the substrate in one steady motion
using just sufficient pressure on the cutting tool to have
the cutting edge reach the substrate, then another five
single lines are cut intersecting the earlier five single
lines. When making successive single cuts with the aid
of a guide, the guide needs to be placed on the uncut
area. After making the required cuts, brushing the film
lightly with a soft brush or tissue to remove any
detached flakes or ribbons of coatings has been done.
Placing the center of the tape over the grid and in the
area of the grid smooth into place by a finger, ensuring
good contact with the film rub the tape firmly with the
eraser on the end of a pencil. Within 90s of application,
the tape has been removed by seizing the free end and
rapidly (not jerked) back upon itself at as close to an
angle of 180° as possible. Inspection of the grid area for
removal of coating from the substrate or from a
previous coating using the illuminated magnifier has
been done and analyzed.
Results can be categorized as ISO Class or according
to ASTM Class. Analyzing the percentage range of
detachment and comparing it with the classification
table, coating adhesion can be classified.
Table 3: Classification criteria of adhesion tape test[12]
Test ISO
Class
DUALSCOPER MP0R is a measuring instrument with
PC-Interface. The probe is placed in the sample surfaces
in different separated positions and the thickness is
showed automatically in the display in µm. Thus,
thicknesses are measured.
4.3 Detergent Test
Detergent Test has been performed for 192 hours. In
this test, a solution of detergent and water has been
made. 50 gm detergents been mixed with 16 litter
waters in a kibble and the three types of coating samples
are sunk for 192 hours at atmospheric temperature. The
samples have been collected after 192 hours from the
detergent bath.
4.4 Salt Spray Test (SST)
During the process of Salt Spray Test, after putting
the three samples inside the chamber, 5% NaCl solution
has been supplied for creating the corrosive
environment.
Chamber needs to maintain several conditions to
support proper testing. Temperature of the chamber has
been conducted at 35 °C with 100% humidity. Collected
fog is 1.61 mL per hour having 7.03 pH and 0.85 mol/L
concentration. Conductivity of collected fog is 61.96
mS/cm. Compressed air pressure is 72.5 Psi, air
saturation pressure and temperate is 14 Psi and 46 °C
chronologically. Duration time of Salt Spray Test is 168
hours and then, the effect of corrosions has analyzed.
The parameters which are needed to consider during
the testing procedure are listed in the table number 4.
Table 4: Parameters of SST
ASTM
Class Parameters Measured Standard
Value Value

If no lattice square is detached and the cut edges 0 5B Test Solution 5% NaCl 2-6% NaCl
are fully smooth solution solution

Temperature of Chamber 35 °C 35±1 °C

Small detachment at the crosscut intersection 1 4B
points and cross cut area is affected less than 5% Humidity of Chamber 100% >95%

Exposure Duration 168 hours As per need

Coating detachment at the crosscut intersection 2 3B
points and/or the edges, cross cut area is Fog Collection 1.61 mL per 1-2 mL per
affected greater than 5% and less than 15% hour hour

pH of Collected Fog 7.03 6.5-7.2

If coating layer is detached partly or wholly in 3 2B Concentration of Collected Fog 0.85 mol/L 0.85 mol/L
great strip and some squares are also detached
partly/wholly, cross cut area is affected greater
than 15% and less than 35% Conductivity of Collected Fog 61.96 mS/cm >50 mS/cm

Compressed Air Pressure 72.5 Psi 57-87 Psi

If coating layer is detached wholly in great strip 4 1B
and some squares are also detached Air Saturator Pressure 14 Psi 12-18 Psi
partly/wholly, cross cut area is affected greater
than 35% and less than 65% Air Saturator Temperature 46 °C 46-49 °C

Interruption of Exposure (for 20 min <60 min

Any level of detachment that can‟t be categorize 5 0B Cleaning and Photography
even by classification 4

4.2 Thickness Test of Coating Layers

Coating thickness has been measured with

© ICMERE 2023
5. RESULT AND ANALYSIS
Adhesion Tape Test, thickness test, detergent test,
Salt Spray Test (SST) are done on Anodized coated,
Electrolytic Deposition coated and Powder coated ADC-
12 samples.

(a) (b)

(a) (b)

(c)
Fig. 6: Detergent Test results of (a) Anodized Coated,
(b) Electrolytic Deposition coated, (c) Powder coated
ADC-12 samples
Salt Spray Test (SST) is conducted for 168 hours and
microstructures are analyzed.
(c)
Fig. 5: Adhesion Tape Test of (a) Anodized Coated, (b)
Electrolytic Deposition coated, (c) Powder coated ADC-
12 samples.
The Adhesion Tape Test of Anodized coated,
Electrolytic Deposition coated and Powder coated
samples respectively shown in Fig. 5. The result is
based on the detached area of coating, the detached area
of the Powder coating is less than 5%, resulting that the
Powder coating remains in the 4B category and (a) (b)
Anodizing as well as Electrolytic Deposition Coating
remain in the 3B category as their detachment area is
12% and 8% respectively.
The thicknesses have been measured of coated layer
can be represented through a table.
Table 5. Measured Coating Layer Thicknesses

Coating Layer Thickness

(micrometer)
Powder coating 88.4 (c)
Fig. 7: Microstructures of (a) Anodized Coated, (b)
Electrolytic Deposition 22.4 Electrolytic Deposition coated, (c) Powder coated ADC-
coating 12 after SST
The surface microstructures shown in the Fig. 7 are
Anodizing 16.2 analyzed and it is observed that Anodizing coated ADC-
12 has less corrosion resistance and there are wounds in
places than the Powder coated and Electrodeposition
Table 5 mentions that Powder coated layer is 88.4 coated samples. Salt Spray Test impacts negligible
µm, Electrodeposition Coating layer is 22.4 µm and effects on Powder coated and Electrolytic deposition
Anodized coating layer is 16.2 µm. coated ADC-12 alloy.
After experimenting detergent test, the results are Powder Coated layer has better adhesion property
such that anodizing shows huge blistering and wear of than Anodized and Electrolytic Deposition Coated layer.
coating whereas powder coating as well as Thickness is also greatest in Powder Coated layer.
electrodeposition coating show very little blistering and Anodized Coated layer has negative effect in detergent
no wear of coating. and salt spray testing. An overall representation of all
those conducted test results and a comparison among
© ICMERE 2023
 coating layers has been shown in table 6. 6. REFERENCES

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© ICMERE 2023

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