NANO-ZIRCONIA COMPOSITE COATINGS AS EFFECTIVE BARRIERS FOR CORROSION MITIGATION

Abstract

This work examines the corrosion resistance of nano zircon or zirconia-silica (ZrO₂-SiO₂) composite coatings on metal surfaces opened to corrosive ambient, comprised of acids, salts, and moisture. Looking at the traditional coatings, nano-scale composites upgrade reliability via augmenting hardness, wear resistance, and adhesion aspects. The synthesized zircon, provide greater cleanliness and steadiness over natural zircon, bring forth remarkable benefits toward industrial usages like aerospace and automotive sectors, diminishing maintenance costs and expanding service span. The ZrO₂-SiO₂ composite was artificially produced by extracting nano ZrO₂ out of zircon concentrate and mixing it with fumed SiO₂ in a 1:1 molar ratio, subsequently calcination at temperatures ranging 1000°C to 1400°C. X-ray diffraction (XRD) study established the configuration of monoclinic ZrO₂ and tetragonal ZrSiO₄, with finest crystallinity at 1400°C. Scanning Electron Microscopy (SEM) exposed a dense, regular, and crack-free coating with tough adhesion. The corrosion rate of mild steel coated with ZrO₂-SiO₂ composite is 0.001mm/year in sea water and .004mm/yr in 0.1M H₂SO₄solution. The results emphasize the prospective of ZrO₂-SiO₂ coatings as a useful resolution for corrosion defence in considerate manufacturing atmospheres.