Numerical modelling on corrosion behaviour of molybdenum-based ceramic nanocomposite coated mild steel using response surface methodology

A novel MoSi2-SiC ceramic matrix nanocomposite was prepared using high-energy mechanical ball milling in various concentrations followed by hot press sintering to generate a target. Ceramic coatings were deposited on mild steel substrates using the MoSi2-SiC target in the RF magnetron sputtering process. The thicknesses of the coatings were controlled and varied between 25, 75 and 125 nm. The morphology of the ceramic nanocoating was explored by XRD, SEM and AFM and the composition of the deposit was analysed by EDX analysis. The corrosion resistance of the MoSi2-SiC coating was evaluated using the acidic bath method by dipping the mild steel substrate in different acid environments (H2SO4, HCl and HNO3) with various concentrations. The results reveal that the prepared ceramic nanocomposites are notably good inhibitors at low concentrations. A response surface methodology (RSM) design tool was used to optimise the corrosion parameters to obtain maximum corrosion resistance and corrosion inhibition efficiency.