Enhanced Mechanical and Electrochemical Performances of Silica-Based Coatings Obtained by Electrophoretic Deposition

To solve the existing problems of silicon dioxide (SiO₂) coating fabricated by the sol-gel method, such as complicated process, long production cycle, uncontrollable quality, etc., an improved electrophoretic deposition (EPD) combined with the sintering process was proposed to prepare SiO₂ coating on a dark nickel (Ni)-coated Q235 steel substrate. Silica sol was prepared by basic catalysis, containing silica of ∼130 g L^-1 with viscosities below 4 mPa s. Silica sol powder was characterized by the differential thermal analysis, Fourier transform infrared spectroscopy, X-ray diffraction, and scanning electron microscopy. EPD was applied to prepare SiO₂ coating on the Ni adhesive layer, followed by the sintering process to improve the compactness. In addition, the effects of EPD and sintering parameters were also evaluated. Potentiodynamic polarization and electrochemical impedance spectra were utilized to assess the corrosion behavior of the coating. The results showed that the EPD coating demonstrated excellent wear resistance when deposited at 15 V for 40 s and sintered at 400 °C for 45 min, exhibiting ∼6 μm thickness and a compact morphology. It also showed superior corrosion resistance with i_corr of 1.02 × 10^-7 A cm^-2, which was 2 orders of magnitude lower than that of dip-coating. Combining the EPD and sintering processes could shorten the fabrication period of SiO₂ inorganic coating and also improve the mechanical and corrosion properties, providing guidance for inorganic ceramic fabrication and showing potential for practical applications.