An experimental and 2D axisymmetric simulation approach for analysing the impact resistance of Zn-ZnO-CaCO₃ coating on AISI 1010 steel

This study seeks to optimize the thickness of the layers formed during the electrodeposition process of Zn–ZnO–CaCO₃ composite on AISI 1010 steel, utilizing both experimental methods and numerical simulations. The study applied DC power voltages of 5 V, 7.5 V, and 10 V to deposit the Zn–ZnO–CaCO₃ composite on AISI 1010 steel, resulting in various layer thicknesses, which were analysed for their microstructure using Scanning Electron Microscopy coupled with Energy Dispersive Spectroscopy (SEM-EDS). Vickers hardness and impact testing, and the finite element method (FEM), indicated that applying a voltage of 5 V produced the densest layer with the highest hardness, measured at 198 HV; increasing the thickness from 19.7 µm to 62.2 µm reduced the maximum stress for samples SP1 and S11 by 20–30% at an optimal thickness range identified as 36–50 µm. These findings emphasize the fundamental significance of optimizing electrodeposition parameters to improve the impact resistance of the coating. • Electrodeposition DC power values of 5 V, 7.5 V, and 10 V were used to deposit the composite, resulting in varying layer thickness. • Electrodeposited mild steel with Zn and Zn-CaCO₃ results in various thicknesses with improved impact resistance. • Controlling electrodeposition parameters enhances impact resistance and interface integrity in industrial applications.