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Effects of Al2O3 Additive on Manganese Phosphate Conversion Coating of Carbon Steel

In this study, the effects of Al2O3 additives on the anticorrosion and tribological properties of Mn3(PO4)2-coated carbon steel were investigated. The microstructure and morphology of the coatings were studied by scanning electron microscopy, X-ray diffraction, energy-dispersive X-ray spectroscopy, and X-ray photoelectron spectroscopy. The Vickers micro-hardness and wear resistance of the produced composite coatings were evaluated and compared with those of the non-composited Mn3(PO4)2 coating. The electrochemical corrosion behaviors of the prepared coatings were investigated in a 3.5 wt.% NaCl solution by a potentiostat–galvanostat device to determine the effects of Al2O3 on the formation of Mn3(PO4)2 coatings on steel. Mn3(PO4)2 composite conversion coatings were successfully created by chemical treatment, with the main component of hureaulite [(Mn,Fe)5H2(PO4)4∙4H2O]. The micro-hardness, wear resistance, corrosion performance, and passivation behaviors of the coatings were improved by adding Al2O3 particles. The optimum concentration of Al2O3 particles in the Mn3(PO4)2 coating to attain the best microstructure, wear resistance properties, and corrosion resistance was 10 g/L.