Effect of Surface Roughness on Crystal Size of Manganese Phosphate Coating of Carbon Steel

In this study, the correlation between surface roughness of carbon steel and crystal size of manganese phosphate coatings has been investigated. The microstructure and surface morphology of the coatings were analyzed by SEM, XRD. The surface roughness test was carried out in order to calculate Ra value by atomic force microscopy (AFM). Also, the tribology property of manganese phosphate coating was tested by ball-on disk. XRD showed that (Mn,Fe)5H(2)(PO(4))(4).4H(2)O in manganese phosphate coating layer was formed by the chemical reaction between manganese phosphate and elements in carbon steel. Also, (Mn,Fe)5H(2)(PO(4))(4) . 4H(2)O was observed to be formed in all manganese phosphate conversion coating. With regard to the effects of surface roughness on manganese phosphate coatings, it can be seen that there is an increase of the crystal size on manganese phosphate coating as the surface roughness of carbon steel decreased. The increase of crystal size by the surface roughness had effect on the tribology property and electrochemical property. It was approved that friction coefficient of manganese phosphate coating is remarkably improved as the surface roughness of carbon steel become rough.