The several types of sonication methods were applied to access the different morphologies of ZnO nanostructures on the surface of mild steel. To achieve this goal, a sonictor equipped with the probe extender was used as a high intensity ultrasonic apparatus for direct sonication. Furthermore, an ultrasonic bath (low intensity) and a cuphorn system (high intensity) were applied for indirect sonication. To find the effect of the acoustic waves on the ZnO morphology, the micrographs of obtained surfaces were compared to the sample prepared by the conventional method using scanning electron microscopy (SEM). In this work, the beneficial effects of sonication were subjected on the breaking down the agglomerates to smaller size particles, metal surface activation, and on the facile approach to nanostructures synthesis. The influence of the resulting ZnO structures over the corrosion protection of the electroless Ni–P alloy coatings was evaluated by the potentiodynamic polarization technique (Tafel extrapolation).

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