Abstract
Arc thermal metal spray coating provides excellent corrosion, erosion and wear resistance to steel substrates. This paper incorporates some results of aluminum coating applied by this method on plain carbon steel. Thereafter, coated panels were exposed to an environment known to form stable corrosion products with aluminum. The coated panels were immersed in Society of Automotive Engineers (SAE) J2334 for different periods of time. This solution consists of an aqueous solution of NaCl, CaCl2 and NaHCO3. Various electrochemical techniques, i.e., corrosion potential-time, electrochemical impedance spectroscopy (EIS) and the potentiodynamic were used to determine the performance of stimulants in improving the properties of the coating. EIS studies revealed the kinetics and mechanism of corrosion and potentiodynamic attributed the formation of a passive film, which stifles the penetration of aggressive ions towards the substrate. The corrosion products that formed on the coating surface, identified using Raman spectroscopy, were Dawsonite (NaAlCO3(OH)2) and Al(OH)3. These compounds of aluminum are very sparingly soluble in aqueous solution and protect the substrate from pitting and uniform corrosion. The morphology and composition of corrosion products determined by scanning electron microscopy and energy dispersive X-ray analyses indicated that the environment plays a decisive role in improving the corrosion resistance of aluminum coating.
Highlights
Steel is being used everywhere in world due to its broad application
These phases are very protective in nature and once these phases are formed on coating surface they protect the materials from further corrosion
These phases are very protective in nature and once these phases are formed on of passive passive film formed formed on the the Al
Summary
Steel is being used everywhere in world due to its broad application. Steel has inherent mechanical properties to a proper extent, but there are some problems related to corrosion, especially in aqueous, dry and atmospheric conditions. The corrosion performance of Al coatings in coastal and open industrially polluted environments showed the enhanced corrosion resistance properties for longer duration of exposure due to the sacrificial nature of Al metal [13] and the formation of naturally occurring protective corrosion products on the coating surface [14]. To evaluate the performance of Al coatings in immersion conditions of SAE J2334 solution; To determine the kinetics and mechanism of corrosion process for Al coatings applied by arc thermal metals spray in the presence of stimulants, i.e., carbonate and chloride ions; To study the role of stimulants on the formation of corrosion products on the surface of Al coatings in SAE J2334 solution; To study the thenature nature of corrosion products formed on Al coating surface in of presence of.
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