Influence of potential on structure and properties of microarc oxidation coating on Mg alloy

In order to obtain optimizing microarc oxidation coating on Mg alloy from a friendly-enviormental electrolyte free of Cr6 and PO43-, constant potential regime was applied to produce it. The influence of potential on the morphology, composition, structure and other properties, such as microhardness and corrosion resistance were investigated by scanning electron microscopy (SEM), energy dispersive spectroscope (EDS), X-ray diffraction (XRD), hardness tester and electrochemical method. The results clearly show that oxidation potential plays an important role in the formation of coating's structure and properties. The microarc oxidation coating is smooth and white, which consists of two layers. The external layer is loose and porous and enriched in Al and Si. Moreover, its content of Al and Si increases with the increasing operated potential. While the inner layer is compact and the content of Al and Si are lower than that of the external layer. The coating is composed of several phases and the major phases are MgA12O4 and MgO, and the minor phases are Al2O3 and SiO2 when the potential is higher. The microhardness of coating is obtained the maximum at the potential of 45 V, so does the corrosion resistance.     

The Microstructure and Properties of Diffusion Layer of Spray Aluminum

After diffusion processing of thermal spraying , aluminum on 20^# steel is discussed in this article. Variations of microstructure, composition as well as mierohardness and corrosion resistatwe of diffusion layer of spray aluminum were explored by means of X-ray diffraction, scanning electron microscopy （SEM） and electron probe microanlysis （ EPMA ） . The result shows that the diffusion layer of spray aluminum consists of η phase （ Fe2Al5 ）, ξ phuse （ FeAl2 ）, β2 phase （ FeA1 ）,β1 plmse （ Fe3Al ） and α pluse from surface to substrate. There are balanced transitions between phases. The layer has extra high hardness and corrosion resistance.     

Microstructure and electrochemical behavior of laser cladded HA coating on pure titanium TA2

Hydroxyapatite (HA, Ca10(PO4)6(OH)2) coating was fabricated on pure Ti (TA2) by laser cladding technology. The phase structure, microstructure, microhardness and electrochemical behavior of the laser cladded HA coating in artificial body fluid were investigated. The results show that the HA coating is mainly composed of highly crystallized HA. A transitional layer between HA coating and Ti substrate is formed. Microhardness measurement shows the gradually increasing of microhardness from 150 HV at TA2 substrate to 600 HV at transitional layer, and followed by a decreasing to 400 HV at HA coated layer. Electrochemical corrosion tests show that the HA coating has higher open circuit potential , lower corrosion current density and corrosion rate in comparison to the TA2 substrate.     

Siliconizing formation mechanism and its property by slurry pack cementation on electro-deposited nickel layer into copper matrix

Silicide coating was prepared on electro-deposited nickel layer by the slurry pack cementation process on copper matrix at 1173 K for 12 h using SiO₂ as Si source, pure Al powder as reducer, a dual activator of NaF+NH₄Cl and albumen (egg white) as cohesive agent. Microstructure, properties and siliconizing mechanism of silicide coating were discussed. The experimental results show that the silicide coating with 220 μm thickness is mainly composed of a Ni₂Si phase and a small amount of Ni₃₁Si₁₂ phase. Its mean microhardness (HV 790) is ten times than that of copper substrate (HV 70). The coefficient of friction decreases from 0.8 of pure copper to about 0.3 of the siliconzed sample. SiF₂, SiCl₂ and SiCl₃ are responsible for the transportation and deposition of Si during the slurry pack cementation process.     

Influence of crucible material on the microstructure and properties of iron rich glass-ceramics

Slag glass melting is usually performed on a laboratory scale in crucibles, which are economically viable tools for the production of slag glass-ceramics. In this work, quaternary CaO-Al₂O₃-MgOSiO₂ (CAMS) glass-ceramics were prepared by melting the tailing of Bayan Obo mine tailing, blast furnace slag, and fly ash in alumina and graphite crucibles. The effect of the crucible material on the microstructure and properties of the glass-ceramics was investigated using differential scanning calorimetry, X-ray diffraction, scanning electron microscopy, energy dispersive X-ray spectroscopy and inductively coupled plasma atomic emission spectroscopy. Results indicated that the contents of Al₂O₃ and Fe₂O₃ in the initial glass were significantly changed by the corrosion of the alumina crucibles during the glass melting process and by the reducing action of the graphite crucibles. The main crystal phases of glass-ceramics melted in alumina crucibles and graphite crucibles were Ca (Mg, Fe, Al) (Si, Al)₂O₆, coesite and Ca (Mg, Al) (Si, Al)₂O₆, respectively. According to these findings, we conclude that the microstructure and properties of the glass-ceramics are affected by the crucibles.     

Corrosion resistance of plasma sprayed NiCrAl+(ZrO2+Y2O3) thermal barrier coating on 18-8 steel surface

The corrosion resistance of NiCrAl+(ZrO₂+Y₂O₃) thermal barrier coating, formed with the plasma spraying technique, on the 18 - 8 steel surface was investigated. The phase structure and morphology of the coating were analyzed by means of X-ray diffraction (XRD) and scanning electron microscopy (SEM). The electrochemical corrosion behavior of the coating in 1.0 mol/L H₂SO₄ solution was studied by using electrochemical measurement methods. The results show that the gradient plasma spraying coating is composed of the NiCrAlY coating and the (ZrO₂+Y₂O₃) top coating, and the coating thickness is 360 μm. The microhardness of coating reaches 1 100 HV. The corrosion resistance of the plasma sprayed coating of the 18 - 8 steel surface is about 5 times as great as that of the original pattern. The corrosion resistance of the coating is enhanced notably. Foundation item: Project (5040202140) supported by Scientific Research Common Program of Beijing Municipal Commission of Education     

Analyses of Microarc Oxidation Coating Formed on AZ91D Alloy in Phosphate Electrolytes

This paper studied the appearance transition of microdischarges, the phase composition and the morphology evolution of the oxide film formed by microarc oxidation on AZ91D magnesium alloy. The appearance of microdischarges population experienced apparent changes in size, spatial density and color, which was related with the changes of the type and quantity of the disintegrated gas bubbles generated at the interface between the electrolyte and substrate. Correspondingly, the diameter of micropores together with net-like fine microcracks increased when a higher voltage was employed. The coating was composed of MgO, MgAl2O4 and there existed a fluoride-enriched zone of about 3-5μm at the film/substrate interface.     

Effect of salt spray corrosion on tribological properties of HVOF sprayed NiCr-Cr<Subscript>3</Subscript>C<Subscript>2</Subscript> coating with intermediate layer

The objective of the present work was to determine the influence of the neutral salt spray corrosion on the wear resistance of HVOF sprayed NiCr-Cr₃C₂ coating with intermediate layer. Ni-Zn-Al₂O₃ coatings as interlayers were prepared by low pressure cold spray (LPCS) between NiCr-Cr₃C₂ cermet coatings to form a sandwich structure to enhance the corrosion resistance properties. The tribological properties were examined using the UMT-3 fricition and wear tester by line-contact reciprocating sliding under dry and salt spray one week corrosion. The morphology, element distribution, and phase compositions of the coating and worn sufaces were analyzed by using scanning electron microscopy, energy dispersive spectrometry, and X-ray diffraction respectively. The corrosion behavior of the coating was studied by the open-circuit potential, the electrochemical impedance spectroscopy, potentiodynamic polarization, and salt spray corrosion methods. It is found that the sandwich structured coating has better corrosion resistance than the single layer coating. The results show that under dry wear conditions, the wear mechanism is abrasive and adhesive wear, whereas under salt spray corrosion conditions it becomes corrosion wear. The friction coefficient of the sandwich structured coating after salt spray corrosion is slightly lower than the dry friction coefficient, but the weight of the wear loss is lower than that under dry condition.     

铝合金微弧氧化生成陶瓷膜的研究

微弧氧化又称阳极火化沉积技术或等离子体增强电化学陶瓷化技术。该技术生成的膜与基体金属结合牢固,厚度可达230μm,绝缘电阻大于100MΩ,硬度达2500HV,大大改善了轻金属的耐磨性、耐蚀性和耐热冲击性,工件尺寸变化小。本文研究在铝合金表面微弧氧化制备陶瓷化氧化膜,以期改善铝合金的耐磨特性。讨论了影响制备陶瓷弧氧化膜的主要因素。     

Investigation on plasma-sprayed ZrO2 thermal barrier coating on nickel alloy substrate

The thermal barrier coatings with NiCrAlY alloy bonding layer, NiCrAlY-Y₂O₃ stabilized ZrO₂ transition layer and Y₂O₃ stabilized ZrO₂ ceramic layer are prepared on nickel alloy substrates using the plasma spray technique. The relationship among the composition, structure and property of the coatings are investigated by means of optical microscope, scanning electronic microscope and the experiments of thermal shock resistance cycling and high temperature oxidation resistance. The results show that the structure design of introducing a transition layer between Ni alloy substrate and ZrO₂ ceramic coating guarantees the high quality and properties of the coatings; ZrO₂ coatings doped with a little SiO₂ possesses better thermal shock resistance and more excellent hot corrosion resistance as compared with ZrO₂ coating materials without SiO₂; the improvement in performance of ZrO₂ coating doped with SiO₂ is due to forming more dense coating structure by self- closing effects of the flaws and pores in the ZrO₂ coatings. Biography of the first author: LU An-xian, Ph.D, professor, born in Jan. 1960, majoring in inorganic non-metal materials.     

Nb质量分数对Al⁃15Si⁃xNb涂层组织与耐蚀性能的影响

以Al?15Si?xNb涂层为研究对象,探究了Nb质量分数对涂层显微组织结构和耐蚀性能的影响规律。采用金相显微镜观察涂层的组织形貌,运用XRD分析涂层的物相组成,应用电化学实验方法（包括开路电位、阻抗谱、极化曲线）表征并讨论了涂层在质量分数为3.5%的NaCl溶液中的腐蚀行为。结果表明,Al?15Si?xNb涂层主要由α?Al、初生Si、共晶Si组成,在涂层中加入Nb元素后生成少量的NbAl₃相和Nb₅Si₃相;Nb元素的加入促进异质形核,较明显地改变涂层的组织分布;Al?15Si?10Nb涂层中的组织更细小且分布更均匀,均匀分布的α?Al、初生Si和共晶Si构成众多均匀分布的腐蚀微电池,促进α?Al阳极反应,使涂层表面生成的Al₂O₃氧化膜更加连续;Al?15Si?xNb涂层的极化曲线具有类钝化特征,其中Nb质量分数为10%时涂层的自腐蚀电位和点蚀电位较高,产物膜电阻较大,维钝电流密度较低,具有更好的耐腐蚀性能。     

Cr-Si-Al复合涂层的结构与耐蚀耐热性研究

应用Ｐ－Ｃ法对中碳钢进行Ｃｒ－Ｓｉ－Ａｌ复合涂覆,用光学显微镜观察了涂层的形貌。用电子 探针及扫描电镜测定了涂层的表面成分及Ｃｒ,Ｓｉ,Ａｌ在涂层中的分布,用Ｘ射线衍射测定了涂层的结构。将经涂覆后的试样进行盐水腐蚀和高温氧化试验,结果表明,其耐蚀和抗氧化性大幅度提高。     

Hot-corrosion mechanism of Ni-Cr coatings at 650°C under different simulated corrosion conditions

The oxidation and lower temperature hot corrosion (LTHC) processes occurring on the surface of Ni-Cr coatings produced by high velocity arc spray (HVAS) were studied. Several different conditions were studied under simulated boiler conditions at 650°C. The protection effect of an Al coating deposited by HVAS onto the Ni-Cr coating was also investigated. Microscope, X-ray diffraction and corrosion rate curves have been used to analyze corrosion mechanisms. The experimental results show that: 1) The oxidation rates are almost superposed in both air (no SO₃) and in simulated coal-fired gas (containing SO₃) as long as no salt was present on the surface. These rate curves show a logarithmic relationship. 2) When the surface is coated with salt (75%K₂SO₃ + 25%Na₂SO₃) the rate curve for LTHC of the Ni-Cr coated surface shows a parabolic shape in the simulated coal-fire flue gas. In air only the oxidation reaction takes place, the second type of LTHC was not seen. And 3) the Al over coating on the Ni-Cr enhances resistance to LTHC because an inter-metallic compound, Al₃Ni₂, forms at the Al/Ni-Cr interface and because of the increase in coating thickness.     

Phase Evolution and Oxidation Resistance of YSZ/(Ni,Al) Composite Coatings in CH<Subscript>4</Subscript> Atmosphere

YSZ/(Ni, Al) composite coatings with different Ni:Al mole ratios were deposited on superalloy Inconel 600 by electrophoretic deposition (EPD) technique, followed by sintering in CH₄ atmosphere at 1 100 °C for 2 h and isothermally oxidation at 1000 °C for 50 h. After sintering at 1100 °C for 2 h in CH₄ atmosphere, besides ZrC and t-ZrO₂ phases, the phase constitutes of Ni:Al mole ratios with 1:3, 1:2, and 1:1 were (Zr, Al)C, AlNi₃ and Ni phases, respectively. A remarkable difference in the oxidation behaviors of YSZ/(Ni, Al) composite coatings with different Ni:Al mole ratios was observed. For YSZ(Ni:Al=1:3) coated sample, oxidation at 1000 °C causes decomposition of the (Zr,Al)C solid solution to metallic Al, and then most of the Al is oxidized to Al₂O₃. For the YSZ(Ni:Al=1:2) coated sample, oxidation at 1000 °C mainly causes decomposition of the AlNi₃ phase. For YSZ(Ni:Al=1:1) coated sample, after oxidation at 1000 °C, most of the Ni is oxidized to NiO phase, and tolerated 50 h of oxidation and finally cracked and spalled from the specimen. YSZ(Ni:Al=1:3) and YSZ(Ni:Al=1:2) coated samples show superior oxidation resistance than that of YSZ coating. The different oxidation resistance mechanisms of YSZ/(Ni, Al) composite coatings sintered in CH₄ atmosphere were discussed.     

Effects of C,N-codoped on the corrosion resistance of TiO<Subscript>2</Subscript> films prepared by plasma surface alloying and thermal oxidation duplex process

C,N-codoped TiO 2 films have been deposited onto stainless steel substrates using plasma surface alloying and thermal oxidation duplex process.Composition analysis shows that the films shield the substrates entirely.The TiO 2 films are anatase in structure as characterized by X-ray diffraction.The electrochemical measurements show that the equilibrium corrosion potential positively shifts from-0.275 eV for bare stainless steel to-0.267 eV for C,N-codoped TiO 2 coated stainless steel,and the corrosion current density decreases from 1.3×10-5 A/cm2 to 4.1×10-6 A/cm2.The corrosion resistance obtained by electrochemistry noise also reveals that the C,N-codoped TiO 2 films provide good protection for stainless steel against corrosion in stimulated body fluid.The above results indicate that C,N-codoped TiO 2 films deposited by plasma surface alloying and thermal oxidation duplex process are effective in protecting stainless steel from corrosion.     

Effect of matrix composition on physical properties of Al<Subscript>3</Subscript>CON in-situ reaction reinforced corundum composite

60% white corundum used for aggregate, 5% aluminium powder for fixed additions and 35% various additives for matrix were prepared for specimens 1#,2#,3#. They were mixed uniformly with the suitable resin as a binder and pressed under pressure of 315 ton forging press, then dried at 200℃ for 24 h. Effects of various additives on 1500 ℃×2 h creep properties of Al3CON reinforced corundum composite were researched. The experimenal results show that creep coefficients of specimens 1#,2#,3# at 1500 ℃×2 h are 1.4×10^- 4, -9.4×10^-4, -22.6×10^-4, respectively. Crushing strength of the slide plate added with suitable additive A after fired at 1500 ℃ ×3 h reaches to 225 MPa, the creep rate is positive all the time from 0% to 0.014% at 1500 ℃ for 2 h. The microstructure result analysis shows that reinforced phases of Al3CON fiber composite have been formed after fired with Al powder in coke at high temperatures for specimen 1#, and the strength of the composite is increased. The hot modulus of rupture is up to 59 MPa at 1400 ℃ and the RUL is obviously higher than that at 1700 ℃. Its service life is two times as that of Al2O3-C slide plate when used in the process of pouring steel. The mechanism of creep rate resistance of the composites can be discovered by means of SEM and EDAX analysis. It is concluded that the active Al3CON and Al2O3 multiphases that were formed by N2 in gas, C, Al and Al2O3 inside the matrix of the composites during in-situ reaction,which gives the composites outstanding creep rate resistance for the dense zone resuiting from Al3CON oxidation that inhibits contraction at the high temperature. Besides, the matrix will turn into the multiphase with high refractoriness, N content and its Al3CON reinforced fiber will further increase accordingly. In addition, Al3CON formed by Al2O3 and C, Al in the matrix with N2 in gas will inhibit the creep rate and also greatly improve the creep rate resistance of the composites.     

Laser cladding Al-Si/Al2O3-TiO2 composite coatings on AZ31B magnesium alloy

To improve the wear resistance and corrosion resistance of magnesium alloys, a 5 kW continuous wave CO₂ laser was used to investigate the laser surface cladding on AZ31B magnesium alloys with Al-Si/Al₂O₃ -TiO₂ composite powders. A detailed microstructure, chemical composition, and phase analysis of the composite coatings were studied by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The laser cladding shows good metallurgical bonding with the substrate. The composite coatings are composed of Mg₁₇Al₁₂, Al₃Mg₂, Mg₂Si, Al₂O₃, and TiO₂ phases. Compared to the average microhardness (50HV_0.05) of the AZ31B substrate, that of the composite coatings (230HV_0.05) is improved significantly. The wear resistances of the surface layers were evaluated in detail. The results demonstrate that the wear resistances of the laser surface-modified samples are considerably improved compared to the substrate. It also show that the composite coatings exhibit better corrosion resistance than that of the substrate in 3.5wt% NaCl solution.     

Microstructure and corrosive property of Ni-P/nano-CeO<Subscript>2</Subscript> coating electrolessly prepared in acidic condition

Electroless Ni-P/nano-CeO₂ composite coating was prepared in acidic condition, and its microstructure and corrosive property were compared with its CeO₂-free counterpart. Scanning electronic microscopy (SEM), transmission electronic microscopy (TEM) and differential scanning calorimeter (DSC) were used to examine surface morphology and microstructure of the coating. Aqueous corrosion was done in 3%NaCl+5%H₂SO₄ solution and high temperature oxidation was done at 750 °C in air. The results showed that Ni-P coating had partial amorphous structure mixed with nano-crystals, while the Ni-P/CeO₂ coating had perfect amorphous structure. At high temperature, Ni3P precipitation and Ni crystallization took place in both coatings at different temperatures. Aqueous corrosion property and high temperature oxidation property of the composite coating were remarkably improved due to the coating’s microstructure change and the rare earth doping effect. During the co-deposition process, some Ce ⁿ⁺(n=3, 4) ions may be adsorbed to metal/solution interface and hinder nickel deposition. Ni-P/CeO₂ coating’s perfect amorphous structure results from the hindered crystal- typed deposition of nickel and the promoted deposition of phosphorous.     

Preparation of Al2O3-SiO2-TiO2-ZrO2 Composite Ceramic Membranes by Sol-Gel Method

Al2O3-SiO2- TiO2-ZrO2 supported membranes were prepared by Sol-Gel method. These composite ceramic membranes are level, even and no macro crack. There exist several crystalline phases such as Al2O3, TiO2 ( anatase ), Al2 SiO5 , and ZrO2 in these membranes. Changing the molar ratio of Al:Si: Ti : Zr ,the kinds and content of crystal phases of composite membranes could be different, which may lend to a variety of microstructure of membranes. The surface nanoscale topography and microstructure of membranes were investigated by XRD, SEM, AFM, EPMA. The effects of additives and heat treatments on the surface nanoscale topography and microstracture of composite ceramic membranes were also analyzed.     

High-temperature oxidation behavior of Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/TiAl matrix composite in air

The oxidation behavior of Al₂O₃/TiAl in situ composites fabricated by hot-pressing technology was investigated at 900° in static air. The results indicate that the mass gains of the composites samples decrease gradually with increasing Nb₂O₅ content and the inert Al₂O₃ dispersoids effectively increase the oxidation resistance of the composites. The higher the Al₂O₃ dispersoids content, the more pronounced the effect. The primary oxidation precesses obey approximately the linear laws, and the cyclic oxidation precesses follow the parabolic laws. The oxidized sample containing Ti₂AlN and TiAl phases in the scales exhibits excellent oxidation resistance. The oxide scale formed after exposure at 900°C for 120 h is multiple-layered, consisting mainly of an outer TiO₂ layer, an intermediate Al₂O₃ layer, and an inner TiO₂+Al₂O₃ mixed layer. From the outer layer to the inner layer, TiO₂+Al₂O₃ mixed layer presents the transit of Al-rich oxide to Ti-rich oxide mixed layer. Near the substrate, cross-section micrograph shows a relatively loose layer, and micro- and macro-pores remain on this layer, which is a transition layer and transferres from Al₂O₃+TiO₂ scale to substrate. The thickness of oxide layer is about 20 μm. It is also found that continuous protective alumina scales can not be observed on the surface of oxidation scales. Ti ions diffuse outwardly to form the outer TiO₂ layer, while oxygen ions transport inwardly to form the inner TiO₂+Al₂O₃ mixed layer. Under long-time intensive oxidation exposure, the internal Al₂O₃ scale has a good adhesiveness with the outer TiO₂ scale. No obvious spallation of the oxide scales occurs. The increased oxidation resistance by the presence of in situ Al₂O₃ particulates is attributed to the enhanced alumina-forming tendency and thin and dense scale formation. Al₂O₃ particulates enhance the potential barrier of Ti ions from M/MO interface to O/MO interface, thereby the TiO₂ growth rate decreases, which is also beneficial to improve the oxidation resistance. Moreover, the multi-structure of the TiO₂+Al₂O₃ mixed layer decreases the indiffusion of oxygen ions and also avails to improve the high temperature oxidation resistance of the as-sintered composites. Supported by the Special Program for Education Bureau of Shaanxi Province, China (Grant No. 08JK240) and Scientific Research Startup Program for Introduced Talents of Shaanxi University of Technology, China (Grant No. SLGQD0751)