Corrosive Media Research Articles

Elevating Oxygen Evolution using Iron Phthalocyanine Infused Vanillic acid Electrocatalyst.

Oxygen evolution reaction (OER) is the bottle neck step in water splitting reaction towards the realization of hydrogen based clean energy production and storage. Metal air batteries and polymer electrolyte membrane fuel cells (PEMFC) are the alternative green energy systems that utilise O2 and H2 in the production of continuous and high energy output without the utilization of carbon based fuels which are the major sources of pollution. Transition metal based N4 organics are explored extensively as oxygen electrocatalysts i. e., OER and oxygen reduction reaction (ORR) catalysts because of their ease of synthesis, tuneable properties, low cost and high performance with long term stability. Here, vanillic acid functionalized iron phthalocyanine (FeVAPc) was synthesised and characterised by various spectroscopic techniques. The novel FeVAPc exhibited good thermal stability and was coated on Ni foam for OER studies. The scanning electron microscopy images showed net-work like surface morphology and the X-ray photoelectron spectroscopy indicated the presence of Fe in +3 oxidation state. The Ni/FeVAPc demonstrated excellent electrocatalytic activity for OER with overpotential of 312 mV at 10 mA.cm-2 current density in 1.0 M KOH electrolyte. The designed organic based catalyst exhibited lesser Tafel slope value which is nearer to the benchmark catalyst, IrO2. The proposed catalyst exhibited good stability as phthalocyanines are highly stable and do not undergo decomposition even in strong acidic and basic corrosive media. Integration of FeVAPc onto the Ni foam resulted in higher mass activity, lower charge transfer resistance, high active surface area leading to enhanced conductivity and activity. The fabricated Ni/FeVAPc is an appropriate cost-effective, efficient and stable catalyst for OER towards industrial applications.

Two schiff base as corrosion inhibitors for N80 in 1.0 M HCl: Experimental and theoretical studies

Two Schiff base inhibitor were synthesized and the structures of RX-1 and RX-2 were confirmed through infrared (IR) and nuclear magnetic resonance spectroscopy (NMR). The corrosion inhibition properties of the two Schiff base inhibitor on N80 steel in 1.0 M HCl were investigated. The results demonstrate that the corrosion inhibition efficiencies of RX-1 and RX-2 at 200 mg/L were 91.15 %, and 91.09 % by weight loss. The results of Electrochemical impedance spectroscopy (EIS) show that RX-1 and RX-2 form adsorption films on the surface of N80 steel to alleviate the corrosion. Tafel polarization curve (TAFEL) results showed that RX-1 and RX-2 reduced the dissolution of N80 by inhibiting both cathode and anode reactions. Scanning electron microscope (SEM), Energy Dispersive Spectrometer (EDS), X-ray photoelectron spectroscopy (XPS) confirmed the effective adsorption of RX-1 and RX-2 on the surface of N80 steel, thereby preventing direct contact between the corrosive medium and the metal. Density functional theory (DFT) Fukui and molecular dynamics simulation (MD) have proved that there are multiple adsorption sites in 1 M HCl at the molecular level, which can be stably adsorbed on the metal surface. Mean Squared Displacement (MSD) has proved that the protective film formed by RX-1 and RX-2 can slow down the corrosion of N80 steel by hindering the diffusion rate of corrosive ions.

Numerical investigation of corrosive gases absorption process by water injection in hydrogenation reaction effluent system

Abstract Water injection for absorbing corrosive gases NH3, HCl and H2S is a widely employed method to mitigate the risk of ammonium salt corrosion in the hydrogenation units. To ensure the efficient prevention of ammonium salt corrosion, a numerical model integrating the hydrodynamics of gas–liquid and the reaction of interphase mass transfer was built based on Euler–Lagrange method in this work. The flow and mass transfer characteristics of complex multi-component system in water injection pipeline were investigated, and the correlation between process operating conditions and gas removal performance was analyzed. The results reveal that the removal efficiencies of corrosive gases in pipeline are influenced by the characteristics of gas–liquid flow and mass transfer, with HCl showing higher removal efficiency compared to NH3 and H2S. Furthermore, the increasing flow rate of water injection, the reducing corrosive medium content and the decreasing droplet diameter have a positive impact on the removal efficiencies of corrosive gases, while the impact of gas-flow velocity on the removal efficiencies of corrosive gases primarily depends on the residence time of droplets. These results have important theoretical value and engineering guiding significance for intensifying the process of water injection in hydrogenation units.

Influence of stacking sequences of woven jute-carbon hybrid composites: Diffusion mechanism and mechanical characterization

In this study, different stacking orders of carbon-jute fiber mats were used to fabricate the composites and hybrids. The impact of different stacking orientations on mechanical properties was investigated experimentally. The experimental results were verified by finite element analysis (FEA). In addition, the impact of the fiber orientation on the loading direction was also investigated. Four layers of fabrics were piled to fabricate the composites by hand-layup with the cold press process. A NaCl solution was used to create a corrosive medium (pH 8), and the composites and hybrids were immersed in that medium, and their mechanical properties were compared. In this research, it has been found that the laminates with the stacking sequence of type-C (C/J/J/C) show the best result among other composites. Jute composites where all the fibers are in the loading direction possess a high strain compared with the other composites and hybrids. On the scanning electron microscope (SEM) image, delamination, buckling of fiber, fiber pullout, and voids were observed. In addition, the kinetics of the diffusion mechanism were also investigated, and it was found from the experimental results that the composites and hybrids immersed in pH 8 absorbed water via Fickian diffusion.

Composite coatings from polycarbosilane derived SiC and Al/SiC cermet active fillers as protective barriers against steel corrosion

Stainless steel is used throughout the world as a structural material. However, it undergoes corrosion damage when exposed to extremely corrosive media, such as the marine environment. An alternative to solve this problem lies in the development of coatings that can withstand extreme conditions but also be easily deposited with inherently corrosion-resistant materials such as silicon carbide (SiC). The present study shows a simple method to produce Al/SiC cermet powders by attrition milling. The resulting cermet powders with a metallic matrix and hemispherical morphology, were employed as fillers in polycarbosilane (PCS) solutions that were sprayed on A304 stainless steel substrates. Al/SiC composite coatings were produced after heating the sprayed suspensions at 700 °C for 1 h in Ar atmosphere. The resulting composite coatings exhibited low surface energies (< 35 mN/m), water contact angles of 53°, and adhesion strength of up to 30 MPa. Finally, corrosion tests were performed in a cyclic corrosion test chamber, showing that these coatings effectively reduced the corrosion rate of stainless steel by 87%, reaching corrosion rate values of 0.007 g/cm2 year.

Study on corrosion resistance of arc sprayed Zn–xAl (x = 19, 27, and 37) pseudo alloy coatings in salt spray environment

AbstractTo study the corrosion behavior of Zn–Al pseudo alloy coatings with different Al contents, Zn–xAl (x = 19, 27, and 37) pseudo alloy coatings were prepared by the wire arc spraying technique using Zn and Al wires with different diameters. This study investigated the microstructure, electrochemical corrosion behavior, and corrosion morphology and products of the as‐sprayed coatings after the salt spray test in 5 wt% NaCl solution. The results exhibited that the Zn–Al pseudo alloy coatings with higher Al content form denser corrosion products (Zn5(OH)8Cl2·H2O and Zn–Al layered double hydroxide) with stronger self‐shielding effect against corrosive media, thus provide better long‐term corrosion protection. Besides, electrochemical reactions are controlled by mass transfer until corrosion for 24 h, and then by a combination of mass transfer and diffusion for 96 h. Overall, it can be concluded that the Zn–37Al pseudo alloy coating in this study shows great potential to protect steel substrates from corrosion.

Ultrathin flaky FeSiAl and Fe3O4@C core-shell integrating the high-performance microwave absorber with gradient anti-corrosion barriers

Heterogeneous interface engineering and magnetic coupling are the main promising strategies for efficient microwave absorbers, but getting them stable in high-salt and humidity environments remains a challenge. Herein, we developed ultrathin flaky FeSiAl(FSA) integrating with Fe3O4@C core-shell for the high-performance microwave absorber with gradient anti-corrosion barriers. The Fe-Prussian blue analogue (PBA) derived microcubes decorated ultrathin FSA are prepared and transformed into Fe3O4@C core-shell in range of 500 ∼ 700 °C. The introduction of ferric oxide favors to impedance matching. Furthermore, the ultra-thin carbon layer and ferric oxide form a hybrid structure, which is conducive to enhancing electron spin and thereby enhancing microwave loss. This hybrid possess enhanced microwave absorption properties with a minimum reflection loss (RLmin) of −45.5 dB at 9.2 GHz at a thickness of 2.5 mm. Moreover, the maximum effective absorption bandwidth value reaches 5.2 GHz from 12.8 to 18 GHz at 1.6 mm. The gradient carbon layers and Fe3O4 provided the bi-barriers towards corrosive medium. Then corrosion resistance of the electric circuit increased up to 3.56×107 Ω∙cm2 for FSA/Fe3O4@C-600. Meanwhile, the corresponding corrosion current decreased into 2.52×10−8 A∙cm−2. Hence, introducing multi-heterointerfaces and dual-magnetic components opens up a fantastic avenue for designing high-efficient absorbers with gradient anti-corrosion barriers.

Study of microstructure and corrosion behavior of nano-Al2O3 coating layers on TiO2 substrate via polymeric method and microwave combustion

The study describes the successful development of a TiO2 ceramic substrate with a protective nano-Al2O3 coating using two different coating techniques: microwave combustion and polymeric methods. The coated ceramics demonstrate enhanced corrosion resistance compared to the uncoated substrate. The optimal TiO2 substrate was prepared by firing it at 1000 °C. This was done to give the desired physical properties of the TiO2 substrate for the coating procedures. Nano-Al2O3 powder was coated onto the surface of the TiO2 substrates. The TiO2 substrates with the Al2O3 coating were then calcined (heat-treated) at 800 and 1000 °C. The structures, morphology, phase composition, apparent porosity, bulk density, and compressive strength of the substrate and coated substrate were characterized. Upon firing at 1000 °C, it was discovered that the two phases of TiO2—rutile and anatase—combine in the substrate. Once the substrate has been coated with nano Al2O3 at 1000 °C, the anatase is transferred into rutile. When compared to the substrate, the coated substrate resulted in a decrease in porosity and an increase in strength. The efficiency of the ceramic metal nanoparticles Al2O3 as a good coating material to protect the TiO2 substrates against the effect of the corrosive medium 0.5 M solution of H2SO4 was measured by two methods: potentio-dynamic polarization (PDP) and the electrochemical impedance spectroscopy (EIS). The results indicated that the corrosion rate was decreased after the substrate coated with alumina from (67.71 to 16.30 C.R. mm/year) and the percentage of the inhibition efficiency recorded a high value reaching (78.56%). The surface morphology and composition after electrochemical measurements are investigated using SEM and EDX analysis. After conducting the corrosion tests and all the characterization, the results indicated that the coated TiO2 substrate prepared by the polymeric method at 800 °C displayed the best physical, mechanical, and corrosion-resistant behavior.

Numerical Study of Solid–Gas Two-Phase Flow and Erosion Distribution in Glass Fiber-Reinforced Polymer Ball Valves

The use of glass fiber-reinforced polymer (GFRP) composites in fluid transport systems can effectively reduce corrosion damage caused by corrosive media. However, collisions between solid particles and the surfaces of ball valve flow passages can cause erosion damage and lead to safety issues. The two-phase flow and erosion characteristics of ball valves manufactured from resin-based fiber-reinforced composite materials were studied under different openings and particle sizes using the CFD-DPM method. The results indicate that both smaller and larger relative openings are prone to erosion damage at the thin edges of the valve ball. As the relative opening increases, the average erosion amount in the flow passage first increases and then decreases. The maximum average erosion amount is 0.0051 kg/m2·s when the relative opening is Cv = 40. At Cv = 40, erosion damage in the flow channel mainly occurs at the bottom of the inlet flow channel and the valve seat position. With increasing particle size, both the average and maximum erosion amounts in the flow channel increase. Larger particle sizes in the inlet flow channel significantly raise the erosion rate nearby, while at other locations, larger particle sizes mainly increase the erosion rate in the same area. During the use of GFRP valves, it is important to avoid introducing large-sized particles into the medium. Keeping the valve’s relative opening greater than 40 and using more erosion-resistant materials for the valve seat can effectively reduce the erosion of the composite ball valve and extend its service life.

Sealing of cerium oxide coating primers on anodized AA2024-T3 alloy by boiling in Lourier buffers

Although their exceptional re-passivation ability, Al-alloys are susceptible to corrosion due to the amphoteric nature of the alumina passivation films. This issue is exacerbated by the disruption of these films by intermetallics on the surfaces of highly doped ones, like AA2024-T3 aircraft alloy. The combination of anodized aluminium oxide (AAO) and cerium conversion coatings (CeCC) shows promise as a coating primer. However, the defective structures of CeO2 and Al2O3 require additional sealing. This research proposes sealing the CeCC/AAO layer by boiling it for 10 minutes in two relatively neutral Lourier buffers, adjusted to pH 7.75, and in a mixture of them. The samples underwent a series of analyses to compare the impact of the sealing procedure on surface topology, properties (e.g., colour and wettability on two samples from each set), and corrosion protective ability. It was assessed after 24 hours of exposure to 3.5 % NaCl model corrosive medium on six samples from each set. The assessments included electrochemical impedance spectroscopy (EIS) and potentiodynamic scanning (PDS) techniques. The results indicate that the borate buffer improves the corrosion protection of the coating primers more effectively than the phosphate and mixed ones.

Physicochemical Properties of (La,Sr)CoO3 Thick Films on Fe-25Cr Steel under Exposure to SOFC Cathode Operating Conditions.

La0.6Sr0.4CoO3 (LSC) coatings with a thickness of 50-100 µm were deposited on Fe-25Cr ferritic stainless steel (DIN 50049) via screen printing. The required suspension had been prepared using fine LSC powders synthesised using EDTA gel processes. In its bulk form, the LSC consisted entirely of the rhombohedral phase with space group R-3c, and it exhibited high electrical conductivity (~144 S·cm-1). LSC-coated steel was oxidised in air at 1073 K, i.e., under conditions corresponding to SOFC cathode operation, for times of up to 144 h. The in situ electrical resistance of the steel/La0.6Sr0.4CoO3 layered system during oxidation was measured. The products formed on the samples after the oxidation reaction resulting from exposure to the corrosive medium were investigated using XRD, SEM-EDS, and TEM-SAD. The microstructural, nanostructural, phase, and chemical analysis of films was performed with a focus on the film/substrate interface. It was determined that the LSC coating interacts with the oxidised steel in the applied conditions, and a multi-layer interfacial zone is formed. Detailed TEM-SAD observations indicated the formation of a main layer consisting of SrCrO4, which was the reaction product of (La,Sr)CoO3, and the Cr2O3 scale formed on the metal surface. The formation of the SrCrO4 phase resulted in improved electrical conductivity of the investigated metal/ceramics layered composite material, as demonstrated by the low area-specific resistance values of 5 mΩ·cm2, thus making it potentially useful as a SOFC interconnect material operating at the tested temperature. In addition, the evaporation rate of chromium measured for the uncoated steel and the steel/La0.6Sr0.4CoO3 layered system likewise indicates that the coating is capable of acting as an effective barrier against the formation of volatile compounds of chromium.

Study of initial corrosion and protection behavior of bronze from the Western Zhou Dynasty assisted by BTA

Electrochemistry methods and surface characteristics were used to investigate the corrosion behaviors in the initial stage and the inhibition efficiency of BTA in simulated soil environments for simulated bronze samples. The results show that the inhibition efficiency can reach 99.96 %; A protrusion morphology of corrosion products formed by PbSO4 with a channel formed by Cu compounds that can transport corrosive media was found in the cross-section of the Pb-rich samples. A mechanism for galvanic corrosion was proposed with the assistance of the inhibition effect of BTA, which can explain the different corrosion behaviors of samples with different Pb contents.

Versatility of Juçara (Euterpe edulis) extracts as corrosion inhibitors of mild steel in different environments: 1 mol L−1 HCl and CO2-saturated formation water

Developing a sustainable and environmentally friendly inhibitor remains an essential and challenging goal for corrosion control. Here, different extracts from the same biomass (Juçara - Euterpe edulis) were applied as a new inhibitor for mild steel in different corrosive medium: 1 mol L−1 HCl (pH 0) and simulated CO2-saturated formation water (pH 5). Depending on the extraction process, the anticorrosive capacity of extracts may increase, a fact verified in gravimetric tests, reaching 94.4% maximum inhibition efficiency for the acidic medium (1000 mg L−1 of Juçara pulp in 48 h of immersion) and 86.1% inhibition efficiency for the saline medium (600 mg L−1 of Juçara pulp extract assisted by ultrasound in 24 h of immersion). Gravimetric tests, electrochemical tests, and surface and biochemical characterization analyses were carried out to better understand these extracts' performance. This work provides an interesting application of the same biomass effectively acting in different corrosive medium, depending on the extraction method.

Valorisation of leather buffing dust as corrosion inhibitor for mild steel in H2SO4 acid

This work discusses the valorisation and efficacy of the acid-extracted collagenous proteins from leather buffing dust (LBD) on the corrosion inhibition of mild steel (MS) in 0.5 M H2SO4 solution using electrochemical analysis. The extract shows ~95 % inhibition efficiency at 1 wt% of raw LBD loading. The inhibitor interaction follows Langmuir adsorption isotherm, indicating monolayer adsorption through physisorption, leading to complex formation on the MS surface. Post-corrosion characterizations reveal film-forming nature of the inhibitor and the involvement of organic compounds in the complex protective layer formation on the MS in the corrosive media. In addition, surface study through an optical profilometer helps to understand the nature of the corroded MS. In summary, the LBD-H2SO4 extract is extremely capable in mitigating the corrosion of MS in H2SO4 solution, and the inhibition phenomenon is governed by a complex passive layer formation on the MS subjected to the corrosive media.

Effects of high-temperature and high-pressure immersion corrosion durations on the fretting tribo-corrosion behaviors of Inconel 690 alloy

An Inconel 690 alloy tube acting as a steam generator tube has been widely applied in the second and third generations of nuclear power plants using pressurized water reactors. However, its entire service process is always accompanied by high-temperature and high-pressure (HTHP) liquid medium corrosion and various fretting mechanical damage behaviors. This study first immerses the Inconel 690 alloy tube in HTHP corrosive medium for different lengths of time (0, 4, 8, and 12 h); then, a fretting tribo-corrosion test rig is used to investigate the effect of different fretting mechanical parameters on the surface damage mechanism and electrochemical dynamic response of each test sample. Results show that the corrosion rate of the Inconel 690 alloy tube has significantly increased after being treated by HTHP immersion corrosion, which is mainly due to the pre-existing corrosion products.

The combined effect of corrosive media and its temperature on the fatigue performance of AA5086-H321 weld joints

This work investigates the fatigue behavior and damage mechanisms in the friction stir weld joints of AA-5086-H321 alloy under the combined effect of media: 3.5 % NaCl and air and its temperature: 24°C and ∼0°C. Sinusoidal loading tests were performed at different load ratios: 0.1 and 0.5, in load-controlled mode at 1 Hz in 3.5 % NaCl. The fatigue lives of the weld joints deteriorated notably under 3.5 % NaCl by selectively attacking its vulnerable nugget zone and heat-affected zone, while the effect of low temperature (∼0°C) was beneficial in both air and 3.5 % NaCl. Two types of crack initiation mechanisms were identified irrespective of the other test conditions: pit-to-pit type, favored at low-stress amplitudes, and pit-to-crack type, favored at high-stress amplitudes. A few cases of crystallographic corrosion pitting were also observed and were accredited to the inherited crystal defects within the Al-matrix. The effect of surrounding temperature was apparent on the crack growth mechanism with limited or no impact on the crack initiation mechanism. The fatigue cracks grew in the intergranular mode under 3.5 % NaCl, while its quantitative presence was decreased at ∼0°C, irrespective of the media, which was attributed as one of the key factors for the increased fatigue performance at ∼0°C.

One-step laser interference lithography for large-scale preparation of a superhydrophobic Ti6Al4V surface with improved hardness, friction reduction and corrosion resistance

Metal workpieces are the bedrock of modern industries as aerospace, marine and car manufacturing. As the pursuit for machinery with excellent performance continues to increase, existing metals are unable to fulfill the requirements of machinery, so surface modification technology has emerged. In this paper, a highly efficient and cost-effective surface modification method using laser interference lithography (LIL) is proposed to prepare superhydrophobic surfaces with corrosion resistance over a large area on Ti6Al4V surfaces. Large-area uniform stripe structures were fabricated on the Ti6Al4V surface by controlling the interference process parameters and spot splicing paths, and then modifying FAS to obtain a superhydrophobic surface. The stripe structure provides more air pockets, which lays the foundation for improved superhydrophobicity and friction reduction. Furthermore, the dense recast layer formed by LIL cauterization completely isolates the Ti6Al4V materials from the corrosive medium, further improving corrosion resistance. The experimental results showed that the hardness reached 15.62 Gpa (313.65 % improvement), the coefficient of friction (COF) was reduced to 0.144 (66.5 % reduction), and the corrosion resistance was improved by two orders of magnitude. As a contactless fabrication technology for periodic structures, LIL has great potential in the field of surface modification.

Phytic acid-doped polypyrrole/graphene oxide nanofillers for the preparation of self-healing anticorrosion coatings with the synergistic physical barrier, passivation and chelating effect

The corrosion protection of organic coatings for metal substrates is generally limited because of the unavoidable coating micropores and cracks, even the coating anticorrosion function will lose when it is damaged. Although the addition of nanofillers into the organic coating matrix can effectively address the above issues, it is challenging to facilely and wholesale construct surface-modified nanofillers with synergistic anticorrosion ability of physical barrier, passivation and chelating effect. In this study, we develop a simple one-pot approach for preparing polypyrrole (PPy) modified graphene oxide (GO) nanofillers with the doping of phytic acid (Ph) (namely GO-PPy@Ph nanoparticles) and then incorporating them into epoxy resin (EP) coating system to form the anticorrosion nanocomposite coatings. The research results display that the GO-PPy@Ph nanoparticles can uniformly disperse in the EP coatings to improve their anti-penetrant ability against corrosive media. And the introduction of GO-PPy@Ph nanoparticles effectively enhances the coating adhesion strength and mechanical performance. Moreover, the anticorrosion tests show that the impedance modulus at 0.01 Hz of GO-PPy@Ph coating after 60-day immersion in 3.5 wt% NaCl solution remains at about 1010 Ω cm2. The dramatical anticorrosive performance of the GO-PPy@Ph coating with self-healing performance is attributed to the synergistic protection of impermeable GO-PPy@Ph nanosheets, passivation function of PPy and metal chelation effect of Ph. This study provides an effective and universal avenue to construct multifunctional nanofillers with the synergistic anticorrosion of high physical barrier, passivation and metal chelating effects for developing anticorrosive nanocomposite coatings with high performances, which have highly attractive potential in the commercialization applications of metal corrosion protection.

Effect of Ce on structural evolution and corrosion resistance of HRB500E rebar corrosion layer

HRB500E rebar is a low-alloy high-strength steel with excellent mechanical properties and good plasticity but suffers from deficient corrosion resistance. This can be solved by adding trace elements, including rare earth elements. Herein, the corrosion-resistant behavior of rebar was evaluated by weightlessness testing and electrochemical measurements, and the effects of Ce on the structural evolution of the corrosion product layer were investigated by scanning electron microscopy (SEM), Electron Probe X-ray Micro-Analyzer (EPMA), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS). The results showed that adding Ce to the rebar improved the densification of the reinforcing surface corrosion products, as well as reduced the corrosion rate of the experimental rebar. Compared to C0 sample without Ce, the rebar sample containing 0.044 wt.% Ce displayed increased Ecorr by 0.051 V, decreased Icorr by 15.573 mA cm−2, enhanced Rc of the corrosion product layer by 112.71 Ω cm2, incremented α-FeOOH content in the corrosion product layer, and boosted ratio of α/γ* in the corrosion product layer by 10.11%. Furthermore, the oxide (CeO2) formed by Ce in the corrosion layer of the rebar bar surface existed in the rust layer, resulting in a stable corrosion product layer with improved blocking ability of the corrosive medium. Overall, the addition of Ce at certain ratios looks promising to produce HRB500E rebar with excellent corrosion resistance and extended service life under harsh conditions.

Wear and corrosion resistance of TiAlSi-Nix (x = 0, 5, 11, 17, 23 at%) multi-principal component alloy coating prepared by ∞ oscillating laser cladding

To improve the wear and corrosion resistance of key components and ensure the safe operation of offshore equipment, we applied an ∞ oscillating laser to prepare a TiAlSi-Ni composite coating. The effects of Ni addition on the composition, microstructure, corrosion resistance and mechanical properties of the coating were experimentally investigated. The results showed that the coating mainly presented an interdendritic - dendritic structure, and the S4 coating with 17 at% Ni had the best wear and corrosion resistance. In the reciprocating sliding friction and wear test at 10 N and 30 N, the wear rates were 0.83 and 1.66 × 10−7 mm2·N−1, respectively, which is 1/5 and 1/3 of TC4 under this load. The S4 also had the largest passivation interval and passivation film stability. The internal and external double-layer film structure ensures that it is not corroded by corrosive medium. The Ti3Al/TiNi semi-coherent interface and lattice distortion gave the Ti3Al-Ti2Ni and TiAl-TiNi eutectic interfaces a high bonding strength. Moreover, the “labyrinth effect” produced by the lamellar eutectic structure further improved the corrosion resistance. This work provides a new method for obtaining coatings with high adhesion and wear and corrosion resistance for offshore platforms.