Hot Corrosion Behavior of Low-Pressure Cold-Sprayed CoNiCrAlY Coatings

CoNiCrAlY coatings were deposited by low-pressure cold spraying and pre-oxidized in a vacuum environment, and its hot corrosion behavior in pure Na₂SO₄ and 75 wt.% Na₂SO₄ + 25 wt.% NaCl salts was investigated. The pre-oxidation treatment resulted in the formation of a dense and continuous α-Al₂O₃ scale on the coating surface. After being corroded for 150 h at 900 °C, the pre-oxidized coating exhibited better corrosion resistance to both salts than the as-sprayed coating. The presence of preformed Al₂O₃ scale reduced the consumption rate of aluminum, by delaying the formation of internal oxides and sulfides and promoting the formation of a denser and more adherent Al₂O₃ scale. Moreover, we investigated the corrosion mechanism of cold-sprayed CoNiCrAlY coatings in the two salts and discussed the effect of the pre-oxidation treatment.     

Corrosion behaviour of AIP NiCoCrAlYSiB coating in salt spray tests

NiCoCrAlYSiB coatings were deposited by arc ion plating (AIP) and annealed/pre-oxidised under various conditions. The corrosion behaviour of as-deposited and annealed/pre-oxidised coatings was studied by salt spray testing in a neutral mist of 5 wt% NaCl at 35 °C for 200 h. The results showed that the as-deposited NiCoCrAlYSiB coating behaved poorly while the annealed and pre-oxidised ones performed much better in salt spray tests. The dense microstructure in annealed coatings and formation of α-Al₂O₃ scales on the surface during pre-oxidation improved the corrosion resistance in salt spray test. The corrosion process was investigated from the aspects of corrosion products, and its electrochemical mechanism was proposed as well.     

Corrosion Behavior and Microhardness of Ni-P-SiO<Subscript>2</Subscript>-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Nano-composite Coatings on Magnesium Alloy

In the present work, nano-composites of Ni-P-SiO₂-Al₂O₃ were coated on AZ91HP magnesium alloy. The surface morphology of the nano-composite coating was studied by field emission scanning electron microscopy (FESEM). The amount of SiO₂ in the coating was determined by energy-dispersive analysis of x-ray (EDX), and the crystalline structure of the coating was examined by x-ray diffractometer (XRD). All the experiments concerning the corrosion behavior of the coating carried out in 3.5 wt.% NaCl solution and evaluated by electrochemical impedance spectroscopy (EIS) and polarization technique. The results showed that an incorporation of SiO₂ and Al₂O₃ in Ni-P coating at the SiO₂ concentration of 10 g/Land 14 g/LAl₂O₃ led to the lowest corrosion rate (i _corr = 1.3 µA/cm²), the most positive E _corr and maximum microhardness (496 VH). Furthermore, Ni-P-SiO₂-Al₂O₃ nano-composite coating possesses less porosity than that in Ni-P coating, resulting in improving corrosion resistance.     

Effect of NaOH on the Structure and Corrosion Performance of Alumina and Silica PEO Coatings on Aluminum

The effect of NaOH content of electrolyte on the properties of ceramic coatings, produced in silicate solution, was studied. Morphology, chemical analysis, phase composition, and cross-section of the ceramic coatings were investigated by SEM, EDS, XRD, and OM, respectively. The corrosion resistance and corrosion mechanism were also studied using potentiodynamic polarization and electrochemical impedance spectroscopy in a 3.5% NaCl solution. To study the surface roughness, a brightness SEM image analysis method was used. Results suggested that increasing the NaOH concentration of sediment production size causes thickness and coating roughness to decrease. The lowest corrosion rate belonged to the twofold layer coating produced in 10 g/L of NaOH. Other samples, with higher concentrations of NaOH, had reduced porosity, and thus an increase in the corrosion resistance was observed. These coatings mainly consisted of α/γ-Al₂O₃ and amorphous silica.     

Corrosion Behavior of Novel Al-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Composites in Aerated 3.5% Chloride Solution

The corrosion behavior of novel Al-Al₂O₃ MMCs was evaluated in aerated 3.5% NaCl solution through potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). These materials corrode almost spontaneously by pitting in aerated 3.5% NaCl solution. Observations indicate that intermetallic particles in these composites appear to play an important role in this pitting corrosion behavior. Addition of Al₂O₃ particles to the base alloys did not appear to increase their corrosion resistance significantly, although corrosion rate was affected by these reinforcement particles. In cyclic polarization experiments, the small difference between the pitting potentials and the repassivation potentials for these MMCs indicated their low resistance to pitting corrosion. EIS measurements indicate adsorption/diffusion phenomena at the interface of the composites. Electrically equivalent circuits are proposed to describe and substantiate the corrosion processes occurring in these materials.     

Combined pre-annealing and pre-oxidation treatment for the processing of thermal barrier coatings on NiCoCrAlY bond coatings

A combined pre-annealing and pre-oxidation treatment was developed for the processing of partially yttria stabilized (PYSZ) thermal barrier coatings (TBC) on top of NiCoCrAlY bond coatings (BC). To develop this pre-treatment, the influence of the oxygen potential during pre-annealing and pre-oxidation on the life span and failure mechanisms of the entire high temperature coating system upon thermal cycling was investigated. The results of this study showed that the service life of the coating system depended strongly on the composition and microstructure of the thermally grown oxide (TGO) after pre-oxidation. The longer life spans were obtained if the TGO thickened very slowly during thermal cycling due to a large α-Al₂O₃ grain size. Such a slow-growing TGO corresponded with a pre-treatment for which θ-Al₂O₃ was formed during pre-oxidation and for which the yttrium was located within a high density of pegs along the TGO/BC interface after pre-oxidation. If the yttrium was present on top of the TGO after pre-oxidation, a thick mixed alumina-zirconia layer formed upon thermal cycling. This mixed oxide layer contributed significantly to the total oxide layer thickness, resulting in short life spans. The formation of NiAl₂O₄ spinel in between the TBC and the α-Al₂O₃ should be avoided, since this can lead to premature failure along the spinel/α-Al₂O₃ interface.     

Cyclic polarization analysis of corrosion behavior of ceramic coating on 6061 Al/SiC<Subscript>p</Subscript> composite for marine applications

The study on the corrosion behavior of the composite and evaluation of surface modification technique are of importance since the addition of reinforcement particles affects the continuity of inherent oxide layer on the matrix and hence its corrosion resistance. The present study deals with the investigations of effect of ceramic coating on the corrosion behavior of 6061 Al/SiC_P (20 volume % reinforcement) composite in 3.5 M NaCl solution at high temperatures namely 30 and 40°C using potentiodynamic polarization technique and cyclic polarization plots. Aluminum coating by magnetron sputtering technique is employed on the composite and it is subjected to heat treatment at 200°C for duration of 2 h for the alumina formation. The alumina coating formed on the composite surface acts as corrosion protective coating. The potentiodynamic polarization technique is used to determine the corrosion rate of the composite specimen with and without ceramic coating in the corrosion media. The cyclic polarization technique is used to study the pitting behavior of the composite with and without ceramic coating. The microstructural analysis is carried out using scanning electron microscopy (SEM). X-RD analysis shows the amorphous nature of Alumina coating obtained on the composite. The results show that the peak aged composite is more prone to corrosion among the aged group of composites but when coated with alumina shows a vast improvement in pitting nucleation resistance even at high temperatures.     

Investigation of Corrosion Protection Performance of Multiphase PEO (Mg<Subscript>2</Subscript>SiO<Subscript>4</Subscript>, MgO,MgAl<Subscript>2</Subscript>O<Subscript>4</Subscript>) Coatings on Mg Alloy Formed in Aluminate-Silicate- based Mixture Electrolyte

Plasma electrolytic oxidation (PEO) coatings in the aluminate-silicate-based mixture electrolyte solution with different duty cycles were successfully applied on Mg alloy. The corrosion behavior of the samples was evaluated by water contact angle test, potentiodynamic polarization, electrochemical impedance spectroscopy (EIS) and immersion tests. Hydrophobic PEO coating could be obtained by adjusting the duty cycle of the applied electric signal. This coating considerably diminished the Mg dissolution and could enhance the impedance values of Mg alloy in 3.5 wt % NaCl solution. However, the surface of other PEO coated samples showed more hydrophilic properties compared to that of the uncoated sample. Dense structure of the modified PEO multiphase (including Mg₂SiO₄, MgO and MgAl₂O₄ phases) coating and also its appropriate thickness provided an effective barrier to remarkably delay corrosive solution penetration into the PEO coating. This phenomenon led to major decrease in anodic current density of alloy in chloride solution.     

Oxidation resistance and corrosion behavior of hot-dip aluminized coatings on commercial-purity titanium

Aluminizing is an effective method to protect alloys from oxidation and corrosion. In this article, the microstructure, morphology, phase composition of the aluminized layers and the oxide films were investigated by SEM, EDS and X-ray diffraction. The high temperature oxidation resistance and electrochemical behavior of hot dip aluminizing coatings on commercial-purity titanium had been studied by cyclic oxidation test and potentiodynamic polarization technique. The results show that the reaction between the titanium and the molten aluminum leads to form an aluminum coating which almost has the composition of the aluminum bath. After diffusion annealing at 950 °C for 6 h, the aluminum coating transformed into a composite layer, which was composed of an inner layer and an outer layer. The inner layer was identified as Ti₃Al or Ti₂Al phase, and the outer layer was TiAl₃ and Al₂O₃ phase. The cyclic oxidation treatment at 1000 °C for 51 h shows that the oxidation resistance of the diffused titanium is 13 times more than the bare titanium. And the formation of TiAl₃, θ-Al₂O₃ and compact α-Al₂O₃ at the outer layer was thought to account for the improvement of the oxidation resistance at high temperature. However, the corrosion resistance of the aluminized titanium and the diffused titanium were reduced in 3.5 wt.% NaCl solution. The corrosion resistance of the aluminized titanium was only one third of bare titanium. Moreover, the corrosion resistance of the diffused titanium was far less than bare titanium.     

Isothermal Oxidation Behavior of NiCoCrAlTaY Coating Deposited by High Velocity Air-Fuel Spraying

The performance of thermal barrier coatings is influenced by the high temperature oxidation behavior of the bond coat. In this paper, NiCoCrAlTaY bond coat was deposited by high velocity air-fuel (HVAF) spraying, and the microstructure and surface morphology of the bond coat before and after oxidation were examined to aim at developing high performance thermal barrier coatings. Results showed that the HVAF sprayed NiCoCrAlTaY coating presented a dense microstructure and some partially melted particles with a near spherical morphology were deposited on the coating surface. A uniform ??-Al₂O₃ scale was formed on the HVAF sprayed MCrAlY coating surface after the pre-oxidation treatment in an argon atmosphere. A small fraction of nodular-shaped mixed oxides was formed when the MCrAlY coating was oxidized for 100?h at 1000?°C. The amount of the mixed oxides increased less significantly after 200?h oxidation. A homogeneous ??-Al₂O₃ oxide scale was maintained over the large particles on the bond coat surface after 200?h oxidation at 1000?°C in air. A model is proposed to explain the formation of nodular-shaped mixed oxides.     

Tribocorrosion Behavior of Fe-Based Amorphous Composite Coating Reinforced by Al<Subscript>2</Subscript>O<Subscript>3</Subscript> in 3.5% NaCl Solution

Although corrosion and friction/wear behavior of Fe-based amorphous coatings and their composites has been extensively studied during the past decade, there is very limited work related to tribocorrosion behavior. In this paper, the tribocorrosion behavior of a Fe-based amorphous composite coating reinforced with 20 wt.% Al₂O₃ particles was investigated in a 3.5% NaCl solution on a ball-on-disk tester and was compared to the monolithic amorphous coating and 316L stainless steel (SS). The results showed that the amorphous composite coating exhibited the highest tribocorrosion resistance among the three materials tested, as evidenced by the lowest coefficient of friction (~0.3) and tribocorrosion wear rate (~1.2 × 10^?5 mm³/N·m). In addition, potentiodynamic polarization measurements before and during tribocorrosion testing demonstrated that corrosion resistance of the amorphous composite coating was not influenced so much by mechanical loading compared to the amorphous coating and the 316L SS. Observations on the worn surface revealed a corrosion-wear- and oxidational-wear-dominated tribocorrosion mechanism for the composite coatings. The excellent tribocorrosion resistance of the composite coating results from the effect of chemically stable Al₂O₃ phase which resists oxidation and delamination during sliding, along with poor wettability with corrosive NaCl droplets.     

Improving the Na2SO4-induced corrosion resistance of Ti3AlC2 by pre-oxidation in air

Ti₃AlC₂ suffers severe Na₂SO₄-induced corrosion attacks at temperatures higher than 800 °C in air. A convenient and efficient pre-oxidation method is proposed to enhance the corrosion resistance of Ti₃AlC₂. The corrosion weight-changes of the pre-oxidized samples were decreased by about four orders of magnitude compared with those of the untreated specimens. The mechanism on improvement of corrosion resistance was investigated by means of thermogravimetric analysis, X-ray diffraction and scanning electron microscopy/energy-dispersive spectroscopy. A continuous and adherent α-Al₂O₃ scale was prepared by high-temperature pre-oxidation treatment in air. The preformed dense Al₂O₃ scale has good compatibility with the Ti₃AlC₂ substrate, and consequently, can act as an efficient barrier against corrosion. Long-time corrosion tests demonstrate that the Al₂O₃ scale conserves after corrosion attack and is capable of long-term stability.     

Corrosion and time dependent passivation of Al 5052 in the presence of H<Subscript>2</Subscript>O<Subscript>2</Subscript>

Corrosion and time–dependent oxide film growth on AA5052 Aluminum alloy in 0.25M Na₂SO₄ solution containing H₂O₂ was studied using electrochemical impedance spectroscopy, potentiodynamic polarization, chronoamperometric and open circuit potential monitoring. It was found that sequential addition of H₂O₂ provokes passivation of AA5052 which ultimately thickens the oxide film and brings slower corrosion rates for AA5052. H2O2 facilitates kinetics of oxide film growth on AA 5052 at 25° and 60 °C which is indicative of formation of a thick barrier film that leads to an increment in the charge transfer resistance. Pitting incubation time increases by introduction of H₂O₂ accompanied by lower pitting and smoother surface morphologies. At short exposure (up to 8 h) to H₂O₂–containing solution, the inductive response at low frequencies predominantly determined the corrosion mechanism of AA5052. On the other hand, at prolonged exposure times (more than 24 h) to 0.25M Na₂SO₄+1vol% H₂O₂ solution, thicker oxide layers resulted in the mixed inductive–Warburg elements in the spectra.     

Corrosion behaviour in alkaline medium of zinc phosphate coated steel obtained by cathodic electrochemical treatment

The present work evaluated the ability of zinc phosphate coating, obtained by cathodic electrochemical treatment, to protect mild steel rebar against the localized attack generated by chloride ions in alkaline medium. The corrosion behaviour of coated steel was assessed by open circuit potential, potentiodynamic polarization and electrochemical impedance spectroscopy. The chemical composition and the morphology of the coated surfaces were evaluated by X-ray diffraction and scanning electron microscopy. Cathodically phosphated mild steel rebar have been studied in alkaline solution with and without chloride simulating the concrete pore solution. For these conditions, the results showed that the slow dissolution of the coating generates the formation of calcium hydroxyzincate (Ca(Zn(OH)₃)₂·2H₂O). After a long immersion time in alkaline solution with and without Cl⁻, the coating is dense and provides an effective corrosion resistance compared to mild steel rebar.     

Microstructure, spallation and corrosion of plasma sprayed Al2O3–13%TiO2 coatings

The electrochemical corrosion behaviours of the steel substrates coated with three different plasma sprayed Al₂O₃–13%TiO₂ coatings were studied in this paper. The three kinds of Al₂O₃–13%TiO₂ coatings were conventional ME coating, nanostructured NP coating and NS coating. There were micro cracks, laminar splats and straight columnar grains in ME coating. For the two nanostructured coatings, the laminar microstructure and columnar grains were not obvious. The NP coating had the highest hardness and spallation resistance. Electrochemical corrosion behaviour of the three coatings was mainly investigated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in aqueous Na₂SO₄ solution.     

Microstructure and corrosion resistance of ceramic coating on carbon steel prepared by plasma electrolytic oxidation

Ceramic coating was prepared on Q235 carbon steel by plasma electrolytic oxidation (PEO). The microstructure of the coating including phase composition, surface and cross-section morphology were studied by X-ray diffraction (XRD), Fourier transform infrared spectroscope (FTIR) and scanning electron microscopy (SEM). The corrosion behavior of the coating was evaluated in 3.5% NaCl solution through electrochemical impedance spectra (EIS), potentiodynamic polarization and open-circuit potential (OCP) techniques. The bonding strength between Q235 carbon steel substrate and the ceramic coating was also tested. The results indicated that PEO coating is a composite coating composed of FeAl₂O₄ and Fe₃O_4. The coating surface is porous and the thickness is about 100 μm. The bonding strength of the coating is about 19 MPa. The corrosion tests showed that the corrosion resistance of Q235 carbon steel could be greatly improved with FeAl₂O₄-Fe₃O₄ composite coating on its surface.     

Corrosion behaviour of polycrystalline Nb<Subscript>2</Subscript>O<Subscript>5</Subscript> thin films and its size effects

This study examines the effect of film thickness ranging from 230 to 404 nm on the corrosion resistance of Nb₂O₅ thin films grown by chemical solution deposition. The films were characterized to obtain the relationships between the deposition parameters and the most relevant physical properties (structural, surface morphology and corrosion resistance). From X-ray diffraction and XPS analyses we can conclude that the films were stoichiometric Nb₂O₅ and crystalline. The internal strain and morphology of the film changes as the number of layers increases indicating a thickness dependent grain size. The surface roughness, corrosion resistance were also affected by the film thickness. Electrochemical impedance spectroscopy (EIS) shows that the thicker film have higher passive and charge transfer resistance than the control samples. These results coating layer of Nb₂O₅ improves the corrosion resistance on an API 5L X80 steel alloy due to the formation of a film on the surface.     

Development of a Pre-Oxidation Treatment to Improve the Adhesion between Thermal Barrier Coatings and NiCoCrAlY Bond Coatings

High-temperature coating systems, consisting of a René N5 superalloy, a Ni–23Co–23Cr–19Al–0.2Y (at.%) bond coating (BC), and a yttria (7 wt%)-stabilized zirconia (YSZ) thermal barrier coating (TBC), were thermally cycled to failure for seven different controlled pre-oxidation treatments and one commonly employed industrial pre-oxidation treatment to establish the preferred microstructures of the thermally-grown oxide (TGO) on a NiCoCrAlY bond coating after pre-oxidation. It was found that the failure of the coating system occurred along the TGO/BC interface when the TGO attained a critical thickness, except if a NiAl₂O₄ spinel layer developed contiguous to the TBC/TGO interface. Then, the coating system failed at a smaller TGO thickness along the NiAl₂O₄/α-Al₂O₃ interface. The value for the TGO thickness at failure increased for a larger area fraction of Y-rich oxide pegs at the TGO/BC interface after pre-oxidation. A desired slow-growing oxide layer on the BC surface was promoted when the presence of the oxides NiAl₂O₄, θ-Al₂O₃, Y₃Al₅O₁₂ at the TGO surface after pre-oxidation was avoided. The α-Al₂O₃ layer, which developed adjacent to the BC upon thermal cycling, grew at a low rate if the initial oxide at the onset of oxidation consisted of θ-Al₂O₃ instead of α-Al₂O₃. Based on these results a pre-oxidation treatment is proposed for which the lifetime of the entire coating system during service is enhanced.     

Improvement in the corrosion resistance of TiB2/A356 composite by molten-salt electrodeposition and anodization

This study reported a novel treatment to improve the corrosion resistance of TiB₂/A356 composites. The method was employed in combination of the molten-salt electrodeposition and subsequent electrochemical anodization technique. By means of molten-salt electrodeposition, the Al coatings were deposited on the surface of TiB₂/A356 composites. It was found that the morphology of the Al coatings is closely related to the current density. Thus, under the suitable condition, a dense and uniform Al coating can be obtained, with the crystal size in the range of 0.5–2 μm and the coating thickness of ~ 9 μm. This continuous Al layer can eliminate the adverse corrosion contribution of TiB₂ particles in Al matrix. The following step of anodization was designed to convert the Al film to an anodized Al oxide film for further corrosion protection. The electrochemical corrosion behavior was evaluated by potentiodynamic polarization curves and electrochemical impedance spectroscopy. These results showed the corrosion resistance was greatly enhanced in TiB₂/A356 composites with an anodized Al-coating than that of the anodized composites. It is evident that the new treatment of metal electrodeposition in molten salts and following anodization is an effective method of anti-corrosion in composites.     

Development and Application of Binary Suspensions in the Ternary System Cr<Subscript>2</Subscript>O<Subscript>3</Subscript>-TiO<Subscript>2</Subscript>-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> for S-HVOF Spraying

Compositions in the system Cr₂O₃-TiO₂-Al₂O₃ are among the most used ceramic materials for thermally sprayed coating solutions. Cr₂O₃ coatings present good sliding wear resistance; Al₂O₃ coatings show excellent insulation behavior and TiO₂ striking corrosion properties. In order to combine these properties, coatings containing more than one oxide are highly interesting. The conventional spraying process is limited to the availability of binary feedstock powders with defined compositions. The use of suspensions offers the opportunity for tailor-made chemical compositions: within the triangle of Cr₂O₃-TiO₂-Al₂O₃, each mixture of oxides can be created. Criteria for the selection of raw materials as well as the relevant aspects for the development of binary suspensions in the Cr₂O₃-TiO₂-Al₂O₃ system to be used as feedstock for thermal spraying are presented. This formulation of binary suspensions required the development of water-based single-oxide suspensions with suitable behavior; otherwise, the interaction between the particles while mixing could lead up to a formation of agglomerates, which affect both the stability of the spray process and the coating properties. For the validation of this formulation procedure, binary Cr₂O₃-TiO₂ and Al₂O₃-TiO₂ suspensions were developed and sprayed using the S-HVOF process. The binary coatings were characterized and discussed in terms of microstructure and microhardness.