Corrosion Resistance Of Coatings Research Articles

Layer-Point Structure of Si3N4-NH2@GO for Improving Corrosion and Wear Resistance of Waterborne Epoxy Coating.

The use of graphene-based materials as anticorrosion coatings to protect metals is always a topic of discussion. In this work, silicon nitride (Si3N4) was aminated to improve its water dispersibility. Then it is attached to the graphene oxide (GO) surface to improve compatibility with epoxy (EP) resin as well as conductivity. The results of Fourier transform infrared (FTIR) spectroscopy, transmission electron microscopy (TEM), scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), and zeta potentials test analyses indicated that Si3N4-NH2@GO with a layer-point structure has been successfully prepared. The corrosion resistance of the composite coatings was characterized by electrochemical impedance spectroscopy (EIS) and polarization curve analysis, and the wear resistance of the composite coatings was tested by friction and wear tests. The results showed that 1.0% Si3N4-NH2@GO has excellent corrosion and wear resistance. The use of Si3N4-NH2@GO layer point structures in this study broadens the way for GO applications.

Two-Dimensional Metal-Organic Frameworks/Epoxy Composite Coatings with Superior O2/H2O Resistance for Anticorrosion Applications.

Corrosion protection technology plays a crucial role in preserving infrastructure, ensuring safety and reliability, and promoting long-term sustainability. In this study, we combined experiments and various analyses to investigate the mechanism of corrosion occurring on the epoxy-based anticorrosive coating containing the additive of two-dimensional (2D) and water-stable zirconium-based metal-organic frameworks (Zr-MOFs). By using benzoic acid as the modulator for the growth of the MOF, a 2D MOF constructed from hexazirconium clusters and BTB linkers (BTB = 1,3,5-tri(4-carboxyphenyl)benzene) with coordinated benzoate (BA-ZrBTB) can be synthesized. By coating the BA-ZrBTB/epoxy composite film (BA-ZrBTB/EP) on the surface of cold-rolled steel (CRS), we found the lowest coating roughness (RMS) of BA-ZrBTB/EP is 2.83 nm with the highest water contact angle as 99.8°, which represents the hydrophobic coating surface. Notably, the corrosion rate of the BA-ZrBTB/EP coating is 2.28 × 10-3 mpy, which is 4 orders of magnitude lower than that of the CRS substrate. Moreover, the energy barrier for oxygen diffusion through BA-ZrBTB/EP coating is larger than that for epoxy coating (EP), indicating improved oxygen resistance for adding 2D Zr-MOFs as the additive. These results underscore the high efficiency and potential of BA-ZrBTB as a highly promising agent for corrosion prevention in various commercial applications. Furthermore, this study represents the first instance of applying 2D Zr-MOF materials in anticorrosion applications, opening up new possibilities for advanced corrosion-resistant coatings.

High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review

AbstractHigh temperature corrosion and slag deposition significantly reduce the thermal efficiency and lifespan of biomass-fired boilers. Surface modification with protective coatings can enhance boiler performance and prevent commercial losses due to maintenance and damage. This review focuses on the development of corrosion-resistant coatings (CRCs) and anti-slagging coatings (ASCs) over the past decade. CRCs are explored through thermal spray processes that include arc spray, atmospheric plasma spray (APS), high-velocity oxygen fuel (HVOF), detonation gun (D-gun™), and cold spray. Studies on alloys, ceramics, and ceramic–metal composites are summarised, highlighting the high temperature corrosion prevention mechanisms and discussing new coating materials. ASCs are reviewed in the context of advancements via thermal spray and slurry spray methods. The mechanisms for slag reduction, testing methods to evaluate ASC effectiveness, and the necessary architecture for preventing slag deposition are examined. A lab-based rig simulating fly ash deposition onto water-cooled coating coupons for anti-slagging investigations is also presented. Further research is needed to develop and evaluate materials for ASCs effectively. Graphical Abstract

Effects of ultrasonic impact treatment on the corrosion resistance of laser-cladded CrMnFeCoNi high-entropy alloy coatings

Ultrasonic impact treatment (UIT) was performed on the surface of the laser-clad CrMnFeCoNi high-entropy alloy coatings. The fluences of the UIT on the microstructure, microhardness, nanoindentation metrics and corrosion resistance of the coatings were explored. Furthermore, the enhancing mechanisms of the corrosion resistance of these coatings by the UIT were clarified. The results showed that the UIT markedly enhanced the corrosion resistance of the laser-clad CrMnFeCoNi high-entropy alloy coatings, and the enhancing effect continuously improved with the increasing of the UIT time. The most significant enhancement of corrosion resistance occurred under the action of UIT with a current of 1.6 A for 20 min. Compared to the untreated group, corrosion potential rose by 65.68 %, corrosion current density fell by 74.95 %, and equivalent resistance increased by 340.37 %. Corrosion morphology analysis showed that the primary forms of corrosion before the UIT were stress corrosion and pitting, which vanished after the UIT with a significant improvement in pitting. Analysis of corrosion products revealed an increased Cr content and a decreased FeOOH and O content on the coating surface after the UIT, leading to enhanced corrosion resistance. Additionally, microstructural analysis showed that large columnar crystals in the laser-clad CrMnFeCoNi high-entropy alloy coatings transformed into finer columns, drastically reducing the grain size of the surface. Concurrently, surface microhardness and nanoindentation mechanical properties markedly improved after the UIT, with the effects growing stronger over time. After the UIT with the current of 1.6 A for 20 min, the increasement of surface microhardness reached 109.01 %. A comprehensive analysis of the fluences on the corrosion resistance of laser-clad CrMnFeCoNi high-entropy alloy coatings by the UIT indicated that the refinement of grain size, improvement of the stress state of the coating, increasement of Cr element and its compounds, and decreasement of FeOOH content are the main reasons of enhanced corrosion resistance.

Carbon dot enhanced electrodeposited coatings for advanced early-stage corrosion sensing

This work explores a novel approach for metal corrosion by integrating carbon dots (CDs) into electrodeposited (ED) coatings. We detail the synthesis and properties of CDs, making them suitable for corrosion detection. Characterization techniques like Fourier Transform Infrared Spectroscopy (FTIR), Scanning electron microscope (SEM), Energy Dispersive X-ray Analysis (EDX), Fluorescent Microscopy and Photoluminescence Spectroscopy (PL).A Design of Experiment (DOE) optimized parameters like CD concentration, curing temperature, and voltage for improved coating performance. The optimized conditions (0.4 wt% M-CDots, 165 °C curing, and 36.2 V) resulted in enhanced adhesion and corrosion resistance.CD-infused coatings demonstrated superior adhesion and mechanical stability compared to controls. Electrochemical tests confirmed a 10 % improvement in corrosion resistance and PL study demonstrated an approximately 60 % enhancement in emission intensity. The adhesion was not affected by introducing carbon dots to the coating. Monitoring the onset of metal corrosion on samples in salt spray cabinets was achieved through the use of a UV source. The photoluminescence of M-CDs offered real-time, non-destructive monitoring of early-stage corrosion through quenching in the presence of exposed metal surfaces.This research presents a significant advancement by integrating CD-based sensing into corrosion-resistant coatings, holding promise for various industries and leading to improved safety, reduced maintenance costs, and extended equipment lifespans. Notably, the biocompatible and disposable nature of CD-based sensors further enhances their practical application.

Carbon Dot Enhanced Electrodeposited Coatings for Advanced Early-Stage Corrosion Sensing

This work explores a novel approach for metal corrosion by integrating carbon dots (CDs) into electrodeposited (ED) coatings. We detail the synthesis and properties of CDs, making them suitable for corrosion detection. Characterization techniques like Fourier Transform Infrared Spectroscopy (FTIR), Scanning electron microscope (SEM), Energy Dispersive X-ray Analysis (EDX), Fluorescent Microscopy and Photoluminescence Spectroscopy (PL).A Design of Experiment (DOE) optimized parameters like CD concentration, curing temperature, and voltage for improved coating performance. The optimized conditions (0.4 wt% M-CDots, 165 °C curing, and 36.2 V) resulted in enhanced adhesion and corrosion resistance.CD-infused coatings demonstrated superior adhesion and mechanical stability compared to controls. Electrochemical tests confirmed a 10 % improvement in corrosion resistance and PL study demonstrated an approximately 60 % enhancement in emission intensity. The adhesion was not affected by introducing carbon dots to the coating. Monitoring the onset of metal corrosion on samples in salt spray cabinets was achieved through the use of a UV source. The photoluminescence of M-CDs offered real-time, non-destructive monitoring of early-stage corrosion through quenching in the presence of exposed metal surfaces.This research presents a significant advancement by integrating CD-based sensing into corrosion-resistant coatings, holding promise for various industries and leading to improved safety, reduced maintenance costs, and extended equipment lifespans. Notably, the biocompatible and disposable nature of CD-based sensors further enhances their practical application.

Effect of Co-Sputtered Copper and Titanium Oxide Coatings on Bacterial Resistance and Cytocompatibility of Osteoblast Cells.

One of the primary risk factors for implant failure is thought to be implant-related infections during the early healing phase. Developing coatings with cell stimulatory behaviour and bacterial adhesion control is still difficult for bone implants. This study proposes an approach for one-step deposition of biocompatible and antimicrobial Cu-doped TiO2 coatings via glow-discharge sputtering of a mosaic target. During the deposition, the bias of the Ti6Al4V substrates was changed. Structure examination, phase analysis, and surface morphology were carried out using X-ray diffraction (XRD) analysis, scanning electron microscopy (SEM), atomic force microscopy (AFM), and X-ray photoelectron spectroscopy (XPS). The hardness values and hydrophilic and corrosion performance were also evaluated together with cytocompatible and antibacterial examinations against E. coli and S. aureus. The results show great chemical and phase control of the bias identifying rutile, anatase, CuO, or ternary oxide phases. It was found that by increasing the substrate bias from 0 to -50 V the Cu content increased from 15.3 up to 20.7 at% while at a high bias of -100 V, the copper content reduced to 3 at%. Simultaneously, apart from the Cu2+ state, Cu1+ is also found in the biased samples. Compared with the bare alloy, the hardness, the water contact angle and corrosion resistance of the biased coatings increased. According to an assessment of in vitro cytocompatibility, all coatings were found to be nontoxic to MG-63 osteoblast cells over the time studied. Copper release and cell-surface interactions generated an antibacterial effect against E. coli and S. aureus strains. The -50 V biased coating combined the most successful results in inhibiting bacterial growth and eliciting the proper responses from osteoblastic cells because of its phase composition, electrochemical stability, hydrophilicity, improved substrate adhesion, and surface roughness. Using this novel surface modification approach, we achieved multifunctionality through controlled copper content and oxide phase composition in the sputtered films.

Enhanced Tribological Behavior and Corrosion Resistance in AlSiC-Based Coatings through Varied Carbon Content

Enhanced Tribological Behavior and Corrosion Resistance in AlSiC-Based Coatings through Varied Carbon Content

Effect of Ti3SiC2 concentration on corrosion resistance and ICR in bipolar plates composite ceramic coatings

Ti3SiC2, a MAX-phase ceramic, amalgamates metallic and ceramic traits, delivering exceptional electrical conductivity and corrosion resistance. In this research, Ti3SiC2 composite coatings were applied to 316 L stainless steel via low-power atmospheric plasma spraying (APS), aiming to bolster the electrical and corrosion resistance attributes of bipolar plates (BPPs). A power input of 15 kW notably enhanced coating density, yielding a Ti3SiC2 concentration of 19.2 wt% in the coating. Extremes in the spraying power led to either diminished deposition efficiency or a reduction of Ti3SiC2 mass fraction below 5 wt%. Tafel curves demonstrated that specimens with elevated Ti3SiC2 mass fractions exhibited robust corrosion resistance, characterized by a self-corrosion potential of −162.5 mV and a self-corrosion current density of 1.7217 × 10−6 A·cm−2. Moreover, the interfacial contact resistance (ICR) between the coating and the gas diffusion layer was remarkably low (down to 5.49 mΩ·cm−2), indicating enhanced surface electron transfer with increasing Ti3SiC2 mass fractions.

A novel siloxene@MoS2 heterostructure for improving the wear and corrosion resistance performance of epoxy coatings

Siloxene (Sic) flakes are two-dimensional silicon-based materials that have been extensively investigated in the domains of batteries, supercapacitors, and electrocatalysis, with essentially no research in the domain of corrosion and wear resistance performance of metal coatings. In this study, Sic sheets were prepared through topological chemical exfoliation and applied to epoxy (EP) resin systems for the first time. The effects of Sic sheets on the corrosion and wear resistance performance of the composite coatings were explored. To improve the enhancement effect of Sic on the tribological properties and corrosion resistance of the composite coatings, molybdenum disulfide (MoS2), which exerts a self-lubricating effect and an enhanced interfacial effect, was grown on the surface of Sic using a hydrothermal method. The corrosion resistance and tribological properties of the prepared composite coatings were characterized through electrochemical impedance spectroscopy, polarization curve analysis, and friction and wear tests. The results indicated that the composite coating containing 0.75wt% siloxene@MoS2 (Sic@MS) has the best corrosion resistance and tribological properties. Compared with the pure EP coating, the wear rate of the Sic@MS coating with the aforementioned concentration was reduced by 67%. Furthermore, the impedance module value at 0.01Hz was increased by three orders of magnitude and the corrosion current density was reduced by three orders of magnitude after 60 days of immersion in NaCl solution. The above results provide a new idea for the application of Sic materials.

Electroactive additives into polyurethanes for high corrosion resistance coatings for mild steel

Electroactive additives into polyurethanes for high corrosion resistance coatings for mild steel

An effective utilization of raw fly ash obtained from thermal power plants using thermal spray technique to improve corrosion resistance for marine applications

Marine-grade steel structures in offshore environments often corrode due to the aggressive environmental conditions. Many ceramic materials can cater to this demand. However, as per economic and ecological concerns, fly ash (FA), an industrial waste, can be another strong contender to control corrosion. Therefore, the present study developed composite coatings of fly ash with additives ((50-48) wt.% Al2O3; 0-2 wt.% carbon nanotube (CNT)) onto marine-grade steel using a plasma spray technique to improve its corrosion resistance. The microstructure of 1 wt.% CNT-reinforced alumina-FA (1CAF) coating was denser than 2 wt.% CNT-reinforced alumina-FA (2CAF) coating due to the uniform dispersion of CNT and, thereby, uniform remelting of coating at localized sites. Consequently, the microhardness and adhesion strength of the 1CAF coating were improved by ∼14.66 % and ∼15.96 %, respectively. Further, Rietveld’s analysis of coatings showed that quartz, being the primary phase for corrosion control, was 19.23 ± 0.87%, 16.33 ± 1.04% and 14.60 ± 1.87% for alumina-FA (AF), 1CAF, and 2CAF, respectively. The electrochemical impedance spectroscopy and the salt spray corrosion tests showed that 1CAF coating corrosion resistance was improved by ∼11.2 % compared to AF coating, even with a lower quartz phase (∼15.08 %) due to the densification of coating. This densification was due to the remelting by CNT to seal pores in the coating. Furthermore, for the same reason, an increase in coating resistance and charge transfer resistance of 1CAF coating by ∼80.9 % and ∼19.93 %, respectively, were seen in the equivalent circuit analysis, showing great promise in controlling interfacial corrosion. Further post-treatments like plasma or laser treatments can seal the coatings further to improve corrosion resistance. Therefore, such coatings are expected to withstand harsh, corrosive environments and are well-suited for marine applications.

An effective utilization of raw fly ash obtained from thermal power plants using thermal spray technique to improve corrosion resistance for marine applications

Marine-grade steel structures in offshore environments often corrode due to the aggressive environmental conditions. Many ceramic materials can cater to this demand. However, as per economic and ecological concerns, fly ash (FA), an industrial waste, can be another strong contender to control corrosion. Therefore, the present study developed composite coatings of fly ash with additives ((50-48) wt.% Al2O3; 0–2 wt% carbon nanotube (CNT)) onto marine-grade steel using a plasma spray technique to improve its corrosion resistance. The microstructure of 1 wt% CNT-reinforced alumina-FA (1CAF) coating was denser than 2 wt% CNT-reinforced alumina-FA (2CAF) coating due to the uniform dispersion of CNT and, thereby, uniform remelting of coating at localized sites. Consequently, the microhardness and adhesion strength of the 1CAF coating were improved by ∼14.66 % and ∼15.96 %, respectively. Further, Rietveld's analysis of coatings showed that quartz, being the primary phase for corrosion control, was 19.23 ± 0.87 %, 16.33 ± 1.04 % and 14.60 ± 1.87 % for alumina-FA (AF), 1CAF, and 2CAF, respectively. The electrochemical impedance spectroscopy and the salt spray corrosion tests showed that 1CAF coating corrosion resistance was improved by ∼11.2 % compared to AF coating, even with a lower quartz phase (∼15.08 %) due to the densification of coating. This densification was due to the remelting by CNT to seal pores in the coating. Furthermore, for the same reason, an increase in coating resistance and charge transfer resistance of 1CAF coating by ∼80.9 % and ∼19.93 %, respectively, were seen in the equivalent circuit analysis, showing great promise in controlling interfacial corrosion. Further post-treatments like plasma or laser treatments can seal the coatings further to improve corrosion resistance. Therefore, such coatings are expected to withstand harsh, corrosive environments and are well-suited for marine applications.

The Improvement in Corrosion Resistance of Electroless Ni-P Coating on Micro-arc Oxidized AZ31 Alloy Prepared with Sodium Dodecyl Sulfate Additive and Post-supercritical CO2 Mixed Electrolyte

The Improvement in Corrosion Resistance of Electroless Ni-P Coating on Micro-arc Oxidized AZ31 Alloy Prepared with Sodium Dodecyl Sulfate Additive and Post-supercritical CO2 Mixed Electrolyte

Enhanced mechanical properties and corrosion resistance of electro-deposited NiCoP composite coatings with ZrB2 particle addition

This work was initiated with the purpose of expanding the utilization of nickel-based composite coatings, especially in wear and corrosion-related industrial applications. NiCoP coatings have long attracted scientific and engineering interest due to their enhanced mechanical properties reinforced by incorporation with a reinforcement phase. In the present study, NiCoP composite coatings reinforced with ZrB2 ceramic particles were synthesized by direct current deposition using a modified Watt’s type bath. The microstructures of composite coatings were studied by x-ray diffraction analysis, energy dispersive x-ray spectroscopy, and scanning electron microscopy, respectively. The hardness and tribological properties of the composite coatings were evaluated and compared. The corrosion behaviors of the deposits were investigated using electrochemical spectroscopy and potentiodynamic polarization techniques in simulated seawater. The effect of ZrB2 content on the microstructures and mechanical properties of the composite coatings was explored and discussed. The present study indicates that there is a progressive enhancement in the hardness, corrosion resistance, and wear resistance of the composite coatings with the increase in ZrB2 loading. The NiCoP-12 g/l-ZrB2 coating possesses the highest microhardness and superior wear performance, while the NiCoP-6 g/l-ZrB2 coating exhibits the best anti-corrosion properties. The present study shows a cost-effective and feasible solution for the preparation of NiCoP protective coatings with enhanced properties, which holds great potential for industrial applications requiring wear and anti-corrosion protection.

Effect of Y2O3 on Microstructure and Corrosion Resistance of Ni45 Coating by Laser Cladding with Different Flow Rates of Carrier Gas

Effect of Y2O3 on Microstructure and Corrosion Resistance of Ni45 Coating by Laser Cladding with Different Flow Rates of Carrier Gas

Self-stabilized styrene-acrylic copolymer latex with heteroatom function for improved water and corrosion resistant coatings

This approach investigates the preparation of a set of styrene-acrylic copolymers incorporated with N-heteroatom in the form of N-vinyl pyrrolidone (NVP) as the functional co-monomer at different concentrations within the range of 17–33 mol%. In this case, self-stabilized copolymer latex was obtained without using any conventional surfactant in the system. The beneficial effect of NVP for the emulsion copolymerization of styrene and butyl acrylate was quantified by preparing and analyzing a control sample of the same copolymer latex that was stabilized by a conventional surfactant. The prepared self-stabilized copolymer latexes having particle sizes of 325–371 nm showed excellent colloidal stability with a zeta potential of >+44.5 mV. The air-dried films were found to be optically transparent and comparable to the control sample. The thermal, structural, microscopic, and water/alkali resistance properties of the films were characterized with respect to the NVP content in the copolymer. The coating characteristics of the copolymers on glass slides and mild steel panels were explored by analyzing the hydrophobicity (water contact angle up to 79°) and corrosion resistance (corrosion rate: 6.03 × 10−5 mm/year) that are significantly improved from the copolymer prepared by conventional emulsion polymerization. This study reveals the impact of N-heteroatom to obtain a self-stabilized polymer latex with improved properties and additional functionalities.

Bacterial and corrosion resistance of polytetrafluoroethylene-silver composite coatings by magnetron sputtering

Titanium alloy and stainless steel implants have been widely applied in orthopedics. However, harmful ions released from implant corrosion caused by human body fluids and bacterial infections may inhibit patients’ recovery. In this work, a polytetrafluoroethylene-silver composite coating was prepared by RF unbalanced magnetron sputtering to improve the bacterial and corrosion resistance of the SS316L. The removal rates of the composite coatings for Escherichia coli and Staphylococcus aureus reached 97.27% and 99.99%, respectively. The contact angle of 131.5° and fluorescence staining experiments show that the composite coating has an antiadhesive effect on bacteria and less cytotoxicity against osteoblasts. The corrosion voltage of the composite coating was much higher than that of the control SS316L substrate, and the corrosion current density was reduced to 1/3, implying the enhancement of the corrosion resistance of the SS316L substrate.

The Effect of Preheating Temperature on the Corrosion Resistance and Porosity Defects Development Behaviour of Ni60A Coating

The laser cladding of nickel-based fusion alloys makes them prone to cracks and defects that affect the overall performance of the coating. In this study, Ni60A coatings were prepared at different preheating temperatures (25 °C, 200 °C, 400 °C and 600 °C). The effect of the preheating temperature of the substrate on the corrosion resistance of the coating as well as on the development of defects were investigated by electrochemical tests and immersion experiments in a 65 wt% H2SO4 solution at 60 °C. The results indicate that preheating the substrate to 200 °C can completely eliminate cracks in the coating and reduce porosity. Preheating leads to a decrease in the corrosion resistance of the coating. The size of the porosity defects is related to the law of longitudinal development of the defects. Porosity defects with diameters smaller than 100 μm have a more pronounced tendency to expand vertically than those with diameters larger than 100 μm.

Investigating the CMAS corrosion resistance and thermal cycling failure behavior of porous thermal barrier coatings with different morphologies prepared by plasma spraying

This study investigates the influence of two-phase powder feeding spacing on the thermal cycling and CMAS corrosion resistance of the thermal barrier coatings (TBCs). Porous thermal barrier coatings with varying microstructures were prepared using the embedded micro agglomerated particle (EMAP) coating preparation method, which is based on conventional yttrium stabilized zirconia (YSZ) coatings. The method involved changing the powder feeding spacing. TBCs' failure mode and microstructure are investigated under complex service conditions. The corrosion resistance, thermal cycling life, hardness, and elastic modulus of TBCs are investigated by thermal cycling-CMAS experiments and isothermal corrosion tests. The EMAP coating has a good service life in the thermal cycling-CMAS tests, with a lower hardness, lower elasticit modulus and larger surface roughness than conventional coatings. This research aims to provide a strategy to optimize structure for TBCs with excellent comprehensive performance.