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.     

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.     

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.     

Pitting corrosion of artificially aged T6 AA2024/SiCp composites in 3.5 wt.% NaCl aqueous solution

The pitting corrosion behavior of the underaged (UA), peakaged (PA) and overaged (OA) T6 AA2024/0, 8, 14, 19, 24 vol.% 40 μm SiC_p(particles) composites was studied. The processing route used for the materials was the compocasting technique. Corrosion potentials (E_cor), pitting potentials (E_pit) as well as protection potentials (E_prot) were extracted from Double Cycle Polarization (DCP) curves contacted in aerated 3.5 wt.% NaCl aqueous solution. In addition 40 days immersion tests carried out and weight loss curves as well as total pit depth measurements were acquired. Pitting initiation and propagation as the main corrosion mechanism was driven by the aging kinetics which is ruled by the reduction in the retained vacancy concentration and at the same time by the increase in dislocation density as SiC_p volume fraction increases. Thus, alteration in pitting behavior among composites of different SiC_p content took place, although their ageing status was exactly the same.     

The effect of heat treatment on the corrosion resistance of 440C stainless steel in 20% HNO<Subscript>3</Subscript> + 2.5% Na<Subscript>2</Subscript>Cr<Subscript>2</Subscript>O<Subscript>7</Subscript> solution

The effect of heat treatment on the corrosion resistance of 440C stainless steel was investigated in a 20% HNO₃ + 2.5% Na₂Cr₂O₇ solution using electrochemical noise (ECN) measurements, electrochemical impedance spectroscopy (EIS), and scanning electron microscopy (SEM) examinations. The noise resistance (Rn), which has been found to be inversely related to the localized corrosion rate, was measured to be 5.7E + 08 Ω-cm², 4.2E + 08 Ω-cm², and 3.7E + 04 Ω-cm² for the oil-quenched, air-quenched, and vacuum furnace cooled (VFC) samples, respectively, after 1200 s exposures. The Rn for all heat treat conditions stabilized within a range of 1.0E + 07 Ω-cm² to 3.2E + 08 Ω-cm² after 2 h exposures. The EIS response showed a polarization resistance (R _p) on the order of 6.6E + 04 Ω-cm², 5.3E + 04 Ω-cm², and 1.1E + 04 Ω-cm² for the oil-quenched, air-quenched, and VFC samples, respectively, after 2 h exposures. The EIS data are in good agreement with ECN data and indicate that after longer exposures, general corrosion mechanisms dominate and the corrosion rates are comparable. SEM examinations of specimens subjected to 1200 s exposures revealed that severity of pitting and intergranular corrosion damage was consistent with trends in the Rn data. Specifically, the electrochemical noise data as well as SEM examinations of specimens revealed a higher localized corrosion resistance of the hardened specimens during the early stages of passivation. This greater resistance to localized corrosion can be attributed to an increased stability of the natural passive film resulting from a higher concentration of chromium atoms in solution for the martensite phase.     

Effect of heat treatment on pitting corrosion resistance of 6061 Al/SiC<Subscript>P</Subscript> composite coated by the cerium oxide film in 3.5 N NaCl solution

One of the main drawbacks of 6061 Al/SiC_P composite is its poor pitting corrosion resistance in the aggressive environment containing chloride ions, such as seawater, for example. The present article deals with the investigations of effects of aging on the corrosion behavior of 6061 Al/SiC_P composite and of the heat treatment on the pitting corrosion resistance of 6061 Al/SiC_P composite coated by cerium oxide prepared by chemical bath technique. Potentiodynamic polarization test was used to study the corrosion behavior of cerium oxide coatings in 3.5N NaCl solution. The microstructure of cerium oxide was examined by scanning electron microscopy (SEM) and the formed phases were identified by X-ray diffraction (XRD). The pitting corrosion resistance of the cerium oxide coating was found to be improved after heat treatment at 300°C for 30 min.     

The Influence of Electrophoretic Potential on Ni—Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Nano-Composite Coating

In this study, the effect of electrophoretic voltage changes on Ni—Al₂O₃ nano-composite coating via two step process electrophoretic, and electrochemically on 1100 Al substrate on morphology, corrosion and wear behaviour were studied. In the first step of deposition for determining the optimum amount of Teri Ethanol Amin activator in electrophoretic suspension Transmission Electron Microscopy (TEM) was used. The amount of alumina particles, Nickel ions in the coating and morphology were studied by Energy-dispersive X-ray spectroscopy (EDX) and Field-Emission Electron Microscopy (FESEM). Nanoparticles distribute more homogenous in deposit within using 40 V voltage. Corrosion behaviour of coating was investigated by polarization technique in 3.5 wt % NaCl which shows a decrease in corrosion current from 13.7 μA/cm² to 1.46 μA/cm² versus bare sample.     

Corrosion behaviour of AA6061 and AA7005 reinforced with Al2O3 particles in aerated 3.5% chloride solutions: potentiodynamic measurements and microstructure evaluation

The influence of the heat treatments on the corrosion behaviour of three aluminium matrix composites (AA6061/Al₂O₃/10p–20p and AA7005/Al₂O₃/10p) has been analysed in an aerated 3.5% sodium chloride solution. Corrosion potentials were determinated in a 3.5% sodium chloride solution (NaCl) using the ASTM standard G69-81 [1]. The galvanic series and the pitting potentials were calculated in this medium for all composites. The following heat treatments were applied on the base composites: (a) as-received state (T4), (b) T6 treatment, (c) an annealing, consisting of a solution stage at 560°C for 3 h for the AA6061 MMC and (d) an annealing at 482°C for 2 h for the AA7005/Al₂O₃/10p, followed by a cooling in the atmosphere furnace. The localised corrosion susceptibility of each material and for each heat treatment were analysed by measurement of the cyclic potentiodynamic polarization. Optical microscopy and SEM metallographic studies were carried out on the samples, before and after corrosion tests, to determine the influence of the microstructural changes during heat treatments on the corrosion behaviour.     

Influence of SiC particles addition on the corrosion behavior of 2014 Al-Cu alloy in 3.5% NaCl solution

The influence of silicon carbide particles (SiC_p) addition on the corrosion behavior of Al-Cu alloy (2014) was evaluated in 3.5% NaCl solution at 30 °C using microstrucural and electrochemical measurements. Addition of 10 wt.% SiC_p to the base alloy is found to increase its corrosion resistance considerably. Incorporation of SiC_p beyond this proportion leads to an increase in corrosion rate of the synthesized composites. Addition of 25 wt.% SiC_p to base alloy decreases corrosion resistances considerably. Microstructural studies reveal the agglomeration of SiC particles in the composites. This results an increase of corrosion reaction with the increase of SiC particles in the composites. EIS measurement indicates the occurrence of adsorption/diffusion phenomena at the interfaces of the composites that ultimately initiate the localized or pitting corrosion.     

Electrochemical corrosion behaviors of amorphous Co<Subscript>69</Subscript>Fe<Subscript>4.5</Subscript>Ni<Subscript>1.5</Subscript>Si<Subscript>10</Subscript>B<Subscript>15</Subscript> alloy

The corrosion behavior of an amorphous Co₆₉Fe_4.5Ni_1.5Si₁₀B₁₅ alloy ribbon was examined as a function of solution temperature (15 °C to 55 °C) and pH (3 to 11). The results of potentiodynamic polarization tests in H2SO4 solution, NaCl solution, and HCl + NaOH solution at various levels of pH showed that the corrosion resistance for the alloy ribbon significantly deteriorated with increasing temperature and decreasing pH for given conditions. The Co₆₉Fe_4.5Ni_1.5Si₁₀B₁₅ alloy was actively dissolved in solutions at pH 3 to 9 but passivated in a solution at pH 11. By comparison of the corrosion behaviors of Co₆₉Fe_4.5(Nb,Cr,Ni)_1.5Si₁₀B₁₅ alloys in the solution at pH 11, Ni was considered to contribute less in improving the corrosion resistance of the alloy than did Cr and Nb.     

Effect of Ti3SiC2 content on the corrosion behavior of Al/Ti3SiC2 composite coatings

The purpose of this study was to investigate the electrochemical corrosion properties of flame-sprayed Al and Al/(5, 10, 15)% Ti₃SiC₂ coatings in a 3.5% NaCl solution. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) were used for analyzing the microstructural characteristics of the coatings. For examining the corrosion behavior of the coatings, a potentiodynamic polarization test and electrochemical impedance spectroscopy (EIS) were used. After the potentiodynamic polarization test, the SEM micrograph of coatings indicated that Ti₃SiC₂ particles played a significant role in pitting corrosion. The results of potentiodynamic polarization tests revealed that Al/Ti₃SiC₂ coating is nobler than that of the pure aluminum coating. On the contrary, the addition of Ti₃SiC₂ particles reduced the process of thickening the passive layer. The results of the EIS tests demonstrated that the presence of Ti₃SiC₂ particles significantly enhances the corrosion resistance of the coatings.     

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 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.     

Wear Performance and Corrosion Behavior of Nano-SiCp-Reinforced AlSi7Mg Composite Prepared by Selective Laser Melting

It is one of the future trends to create materials in situ by laser additive manufacturing. AlSi7Mg/nano-SiCp composites were successfully in situ prepared by selective laser melting in our previous study. After adding 2 wt% nano-SiC particles, the tensile stress and strain increased to 502.94 ± 6.40 MPa and 10.64 ± 1.06%, respectively. For the first time in the present study, we systematically studied and compared the wear performance and corrosion behavior of AlSi7Mg with its composite. We conducted the ball-on-fl at frictional wear test at room temperature, potentiodynamic polarization, electrochemical impedance spectroscopy(EIS), and the immersion corrosion tests in 3.5 wt% NaCl solution. The results showed that composite had higher wear resistance, while AlSi7Mg was more resistant to pitting corrosion. However, the further pitting corrosion of composite was restrained because of the in situ phase nano-Al_4C_3 and the residual nano-SiCp.     

Dual-Layer Oxidation-Protective Plasma-Sprayed SiC-ZrB<Subscript>2</Subscript>/Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-Carbon Nanotube Coating on Graphite

Graphite is used in high-temperature gas-cooled reactors because of its outstanding irradiation performance and corrosion resistance. To restrict its high-temperature (>873 K) oxidation, atmospheric-plasma-sprayed SiC-ZrB₂-Al₂O₃-carbon nanotube (CNT) dual-layer coating was deposited on graphite substrate in this work. The effect of each layer was isolated by processing each component of the coating via spark plasma sintering followed by isothermal kinetic studies. Based on isothermal analysis and the presence of high residual thermal stress in the oxide scale, degradation appeared to be more severe in composites reinforced with CNTs. To avoid the complexity of analysis of composites, the high-temperature activation energy for oxidation was calculated for the single-phase materials only, yielding values of 11.8, 20.5, 43.5, and 4.5 kJ/mol for graphite, SiC, ZrB₂, and CNT, respectively, with increased thermal stability for ZrB₂ and SiC. These results were then used to evaluate the oxidation rate for the composites analytically. This study has broad implications for wider use of dual-layer (SiC-ZrB₂/Al₂O₃) coatings for protecting graphite crucibles even at temperatures above 1073 K.     

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.     

Electrochemical Corrosion of HVOF-Sprayed NiCoCrAlY Coatings in CO<Subscript>2</Subscript>-Saturated Brine

The effect of pre-oxidation treatment and surface preparation of optimized NiCoCrAlY coatings deposited by high-velocity oxygen fuel (HVOF) spraying and exposed to a low-temperature corrosive environment is reported herein. Coatings with two surface finish conditions (as-sprayed and ground) were heat treated under two different oxygen partial pressures (air and argon). The electrochemical corrosion behavior was evaluated in CO₂-saturated brine via potentiodynamic polarization, polarization resistance, and electrochemical impedance measurements. The results show that the grinding process and pre-oxidation treatment in argon enhanced growth and formation of α-Al₂O₃ scale. The potentiodynamic polarization results show that both pre-oxidation and surface treatment had a positive influence on the corrosion resistance of the coating. The reduction of the porosity and the formation of a dense, uniform, and adherent oxide scale through pre-oxidation treatment led to an increase of the corrosion resistance due to a decrease in active sites and blocking of diffusion of reactive species into the coating. However, according to the results, complete transformation from metastable alumina phases to α-Al₂O₃ in addition to formation and growth of dense α-Al₂O₃ is required to ensure full protection of the coating and base material over long periods.     

Preparation of spherical spinel LiCr<Subscript>0.04</Subscript>Mn<Subscript>1.96</Subscript>O<Subscript>4</Subscript> cathode materials based on the slurry spray drying method

Regular spherical chromium doped spinel lithium manganese oxides (LiCr_0.04Mn_1.96O₄) with an average particle size of about 20 μm were prepared by the slurry spray drying process. The materials were compared with non-spherical LiCr_0.04Mn_1.96O₄ materials prepared by the common drying process, and all materials were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), laser particle analyzer and Brunauer-Emmett-Teller (BET) specific surface area test. Electrochemical performances of these cathode materials were studied by cyclic voltammetry (CV), electrochemical impedance spectroscopy (EIS) and Li/LiCr_0.04Mn_1.96O₄ battery test. The results show that the spherical active material is single spinel structure, compact, and with narrow particle size distribution and low BET specific surface area. Compared with the non-spherical material, the spherical material prepared by the spray drying process shows a lower electrochemical impedance, a fewer electrochemical polarization and a better charge/discharge rate capability and capacity retention at elevated temperatures.