| Summary: | The application of rational design principles and process in electrodeposition can eliminate many engineering catastrophes related to corrosion and micromechanical failure in service. This has led to appreciate the need of surface modification on component for enhance life span. Admixed Zn-30Al-13Ti-chloride composite bath was electrolytically prepared and successfully deposited on UNS G10150 mild steel substrate by zinc dual anode deposition processes within an interval of applied current density, particle concentration and constant time. The codeposition of Zn-Al-Ti coating was studied in the presence of other bath ingredient. The effect of deposition current and particle concentration on structural property, adhesion behaviour, ideal crystal orientation, surface topography and electrochemical properties of Zn-Al-Ti alloy coating series on mild steel were analytically examined. The wear stability of the developed composite materials was examined via sliding reciprocating rig. The structural integrity was examined with scanning electron microscope equipped with EDS, X-ray diffraction; Atomic force microscope, dura scan micro-hardness tester and 3 μ metrohm Potentiostat/galvanostat. Interestingly the induced activity of the Zn-Al-Ti chloride composite alloy results into excellent structural modification and stable crystal precipitation within the structural interface as a result of Zn3Al, Zn2Ti and ZnAl3Ti2 intermetallic phase. The obtained results showed that the introduction of Ti particles in the presence of other bath additive in the plating bath mostly modified the surface and brings an increase in the microhardness, corrosion resistance and reduce wear deformation of Zn-Al-Ti chloride composite alloy. Keywords: Crystal growth, Interface, Wear, Corrosion, Coating, Deposition
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