Nurmala S. Dera, Yustina M. Pusparizkita, Surya M.P. Hidayat, Vivi A. Fardilah, M.D.P. Lamura, Hasyid A. Wicaksono, J. Jamari, Athanasius P. Bayuseno
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. © 2026 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC license. http://creativecommons.org/licenses/by-nc/4.0/
Department of Mechanical Engineering, Faculty of Engineering, Diponegoro University, Central Java, Semarang, 50275, Indonesia; Department of Environmental Engineering, Faculty of Engineering, Diponegoro University, Semarang, Indonesia; Department of Mechanical Engineering, Universitas Negeri Surabaya, Surabaya, 60232, Indonesia; Department of Mechanical Engineering, Faculty of Engineering and Science, Universitas Pembangunan Nasional Veteran Jawa Timur, East Java, Surabaya, 60294, Indonesia
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