Summary Corrosion data exist for a wide range of coating materials deposited by different techniques; however, as mentioned earlier, not all coating data can be compared directly because of variations in substrate material and surface preparation, the use sometimes of bond coatings and intermediate layers, the deposition parameters, coating thickness, coating porosity and surface finish, the use sometimes of posttreatmnts, the type of corrosion test performed, test conditions (e.g., solution concentration, temperature, pH, agitation), and interpretation and reporting of the results. With this caveat in mind much of the data presented in this paper has been collected together for convenience as Table X. To compare different coatings, as part of a selection process for a given application, the text (and original sources, if necessary) should be consulted for details of how the coatings were prepared and the tests performed to obtain the given data. In general it seems that there are a number of nickel and cobalt containing alloys, as well as a few inorganic (e.g., SiO2) and organic (e.g., DLC) coatings, that perform very well in terms of corrosion resistance. In the selection of substitutes for decorative and functional chromium coatings the following points should be taken into consideration. o 1. Besides corrosion resistance, other properties may be important and should be taken into account (e.g., hardness, wear resistance, appearance/color). 2. Electrolytic and electroless coating techniques are useful but usually require a postdeposition heat treatment to remove any occluded hydrogen: the heat treatment often modifies the properties of the coating and can affect substrate properties. 3. Coatings applied by “dry” techniques, such as PVD and HVOF thermal spraying avoid any problems with hydrogen embrittlement (unless the substrate pretreatment includes an acid cleaning or activation step). 4. Diffusion/cementation coating techniques can provide thick, adherent coatings on parts with simple geometries, but cannot be used for heatsensitive substrate materials (e.g., high strength steels). 5. Constituents of alloy coatings can be susceptible to preferential attack in aggressive environments, but this may be used to advantage for stripping coatings. 6. The salt fog test, although providing results in a short time period, cannot be related to in service use in most cases: a cyclic corrosion test is becoming more popular and field tests are the most informative if sufficient exposure time is available. Finally, there is no single substitute that meets all the desirable performance characteristics of chromium. Many original equipment manufacturers in the automotive, aerospace, appliance, furniture, plumbing, and architectural hardware industries, for example, have researched alternative coatings and have chosen their preferred solutions, such as electroless Ni-P, electroplated Sn-Ni alloys, and WC-Co coatings, for specific applications. Investigations continue, however, especially in the defense industrial base, where existing specifications or mission safety requirements make substitution more difficult, and because alternatives containing nickel may not be acceptable. The latter metal is included in the list of 17 high-priority chemicals for voluntary reduction published by the EPA.
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