Corrosion Resistance Of Coatings Research Articles

Improvement of the Abrasion and Corrosion Resistance of a Waterborne Epoxy Coating by α-ZrP@PTA-Ce(III) with Dual Corrosion Inhibition Effects

Improvement of the Abrasion and Corrosion Resistance of a Waterborne Epoxy Coating by α-ZrP@PTA-Ce(III) with Dual Corrosion Inhibition Effects

Plasma‐Generated Luminescent Coatings: Innovations in Thermal Sensitivity and Corrosion Resistance

AbstractThe strategic design of traditional coating materials has long been pivotal in broadening their range of applications. In this work, europium‐doped TiO2 coatings are grown in situ on the surface of titanium substrate using plasma electrolytic oxidation technology. The core reaction took no more than five minutes. Incorporating europium into the coating preserved the inherent corrosion resistance of PEO coatings while imparting anticipated thermal‐sensitive luminescence capabilities. The intrinsic emission of TiO2 and the characteristic emission of Eu3+ (5D0 → 7F2) are employed as the self‐reference for the LIR thermometry. The absolute and relative temperature sensitivity of the coating reached 0.0087 K−1 and 0.739% K−1, respectively. Notably, the coating exhibited a signal discriminability of up to 5100 cm−1 and a temperature uncertainty of only 0.18 K, which is comparable to some TiO2: Eu nanoparticles. The ingenious fusion of corrosion resistance and thermal‐sensitive luminescence of the coating not only makes it a classic protective structure but also facilitates its applicability to diverse scenarios, including optical thermometry in extreme environments.

Preparation of SiO2 solvent-free nanofluids for modification of commercial corrosion-resistant coatings

Preparation of SiO2 solvent-free nanofluids for modification of commercial corrosion-resistant coatings

Advanced corrosion resistance and mechanistic insights of electroless Ni-P-PTFE coatings on L245NS substrate in H2S-saturated environments

The extraction and transportation of oil and gas pose significant challenges due to corrosive environments, particularly hydrogen sulfide (H2S) exposure. This study investigates the use of polytetrafluoroethylene (PTFE) to enhance the corrosion resistance of nickel‑phosphorus (NiP) coatings in H2S-rich environments. Electroless deposition was employed to prepare Ni-P/PTFE coatings, which were then subjected to simulated H2S corrosion tests. Results indicate that the incorporation of PTFE led to a more uniform NiP coating with reduced porosity, significantly improving corrosion resistance. The coatings exhibited enhanced protective performance by stabilizing corrosion product layers and preventing the formation of corrosion channels. Ni-P-PTFE coatings overcame the existing research challenge of NiP coatings' corrosion in H2S environments, showing no penetration of the corrosive medium into the substrate after 720 h of immersion. The corrosion rate of the coating is only 0.0261 mm/year, only 4.27 % of the corrosion rate of the L245NS substrate in the early stage of corrosion. Moreover, after characterization by SEM, XRD and XPS, it was found that the presence of PTFE altered the corrosion mechanism, promoting the formation of stable nickel sulfide and oxide layers on the surface. This study sheds light on the mechanisms underlying PTFE-enhanced corrosion resistance in NiP coatings, offering promising implications for extending the lifespan of equipment in the oil and gas industry.

Effect of silica‐loaded polydopamine‐modified graphene oxide nanocomposites on the corrosion resistance of polyester coatings

Effect of silica‐loaded polydopamine‐modified graphene oxide nanocomposites on the corrosion resistance of polyester coatings

Precisely regulated crystalline phase of TiO2@composite G doped with Al3+: For the preparation of highly conductive, corrosion resistant conductive coatings

The development of conductive materials is crucial to the upgrading of modern science and technology industries. In recent years, the research on conductive materials synthesized based on TiO2 has mainly focused on improving the conductivity and stability of the materials. And this study, based on the high conductivity of the material, innovatively proposes a method to precisely regulate the crystal phase and morphology of TiO2 by CH3COOH and temperature together. Meanwhile, the heterostructure was successfully built by doping Al3+ into the TiO2 lattice, and a new conductive pathway (Al-O-C) was constructed. Finally, the composite G was prepared as an Al3+-doped TiO2 composite G (Al-T/G) functional material, and it was verified by first-principles calculations (DFT). The experimental results show that the Al-T/G material not only has the low surface resistance and high whiteness of TiO2, but also is endowed with more excellent resistivity (0.203 Ω·cm) and protection efficiency (92.45 %). Meanwhile, compared with the conventional antimony-doped tin dioxide (ATO) conductive materials, the Al-T/G functional materials prepared in this paper are basically harmless to the environment in the experimental process while ensuring high conductivity. Most importantly, this paper explores the bonding mechanism of Al3+-doped TiO2 conductive materials, which provides new insights and ideas in the field of dopant-modified TiO2 conductive materials.

Enhanced steam thermal cycle resistance of Yb2Si2O7 environmental barrier coatings via Al modification

SiC-based ceramic matrix composites are susceptible to performance losses in steam environments, necessitating the use of environmental barrier coatings for their protection. The high Si activity of Yb2Si2O7 material may induce the emergence of Si(OH)4 in steam environments, resulting in the development of a pore structure within Yb2Si2O7. This pore structure weakens the service life of the coating, highlighting the importance of enhancing the steam corrosion resistance of environmental barrier coatings as a key factor in improving their overall longevity. In the present study, we employed Al modification technique to improve the steam corrosion resistance of Yb2Si2O7 coatings. The results indicated that Al-modified Yb2Si2O7 coatings exhibited superior steam thermal cycle corrosion resistance compared to the non-modified Yb2Si2O7 coatings after testing performed at 1523 K for 1000 h (10 h per cycle). This improvement was attributed to the presence of Yb3Al5O12 and Al2O3 composite phases within the Al-modified Yb2Si2O7 coatings, which exhibited low steam activity and effective steam corrosion resistance. Moreover, Al-modified Yb2Si2O7 coatings obtained the dual excellent performance of improving the steam corrosion resistance of Yb2Si2O7 coating and not weakening the thermal cycle ability, providing a guarantee for the longer life of Yb2Si2O7 coating.

Fabrication of Corrosion-Resistant Superhydrophobic Coatings and Impermeable Porous Structures Using Fluorinated Microemulsions Containing Thermally Decomposable Surfactants

Fabrication of Corrosion-Resistant Superhydrophobic Coatings and Impermeable Porous Structures Using Fluorinated Microemulsions Containing Thermally Decomposable Surfactants

Characterization of Nano-kaolin and its enhancement of the mechanical and corrosion resistance of epoxy coatings

This study compares the effects of varying concentrations of nano-kaolin and titanium dioxide on the mechanical and corrosion resistance of epoxy coatings. Characterization techniques such as TEM, XRD, Raman, FTIR, XPS, and AFM revealed surface features of nano-kaolin: the particle size reached the nanoscale, the XRD diffraction peak at 2θ = 25.3° disappeared, Raman peaks broadened with decreased intensity, and a blue shift occurred in the FTIR spectra for various functional groups. Compared to pure epoxy coatings, the composite epoxy coating with 10 wt% nano-kaolin showed an 83.87 % increase in adhesion, an 81.82 % improvement in impact resistance, and a 61.42 % reduction in friction coefficient; while a 20 wt% titanium dioxide composite coating showed a 74.19 % increase in adhesion, a 75.76 % improvement in impact resistance, and a 46.9 % reduction in friction coefficient. Electrochemical tests indicated that a composite coating with 10 wt% nano-kaolin, after soaking in 3.5 wt% NaCl solution for 960 hours, achieved a corrosion efficiency of 98.87 % and an impedance modulus of 108.8Ω.cm2, which was three orders of magnitude higher than that of pure epoxy resin, increasing corrosion resistance by 57.14 %; whereas a 20 wt% titanium dioxide composite coating reached a corrosion efficiency of 89.29 % and an impedance modulus of 106.6Ω.cm2 after the same conditions, increasing corrosion resistance by 17.86 % compared to the pure epoxy resin. The composite coating with 10 wt% nano-kaolin exhibited superior mechanical and corrosion resistance, outperforming the 20 wt% titanium dioxide coating. Mechanical and corrosion mechanisms suggest that the uniformly dispersed nano-kaolin inhibits interactions between epoxy resin molecules and carries the external load, thereby enhancing intermolecular cohesion. Improved adhesion and impact resistance indirectly extend the coating's lifespan by prolonging the path of corrosion media through the coating to the substrate. The novel coating modification method proposed in this study effectively replaces titanium dioxide and enhances the coating's mechanical and corrosion resistance, offering a new solution for corrosion prevention in metal materials.

Improving the Corrosion Resistance of Carbon Steel Via Aluminum-Based Coating from Ionic Liquid Electrolytes at Room Temperature

Improving the Corrosion Resistance of Carbon Steel Via Aluminum-Based Coating from Ionic Liquid Electrolytes at Room Temperature

Effects of Cr3C2 addition on microstructure and corrosion properties of Cr3C2/15–5PH composite coatings on 12Cr13 by laser cladding

The application of laser cladding technology to prepare iron-based composite coatings has significant advantages in improving the surface properties of 12Cr13 stainless steel. 15–5PH composite coatings reinforced with Cr3C2 particles of different contents (0–25 wt%) were prepared on the 12Cr13 surface by the coaxial powder feeding laser cladding system. The microstructure, phase composition, element distribution, corrosion resistance and corrosion mechanism of the composite coatings were analyzed and studied by optical microscope, scanning electron microscope, X-ray energy dispersive spectrometer, X-ray diffractometer and electrochemical workstation. The results indicated that the Cr3C2/15–5PH composite coatings exhibited good macroscopic morphology and dilution rate under appropriate laser cladding process parameters. The addition of Cr3C2 particles changed the main phase from α-Fe to γ-Fe and formed new carbide phases (M7C3 and Cr23C6). The Cr3C2/15–5PH composite coatings exhibited a typical microstructure with rapid solidification characteristics, and the addition of Cr3C2 significantly changed the grain size. The distribution of Fe, Ni, and Cr elements in the composite coatings was uniform, and the relative content of Cr elements increased and remained at high level. The 15-5PH composite coating with 15 wt% Cr3C2 exhibited a lower corrosion current density and higher impedance modulus values. The surface of this composite coating had no obvious corrosion pits, and the passive film effectively retarded the further corrosion by the Cl- ions on the surface during the electrochemical corrosion process. By preparing a 15–5PH composite coating with 15 wt% Cr3C2 on the surface of 12Cr13, the corrosion resistance of the surface can be effectively improved.

Investigation of in-vitro bioactivity, electrochemical corrosion, wettability and adhesion properties of bioglass-based coatings modified with Y2O3 and Zr on novel β-type Ti-30Zr-5Mo alloys

In this study, the in-vitro bioactivity, electrochemical corrosion resistance, wettability, and adhesion properties of bioglass-based coatings modified with Y2O3 and ZrO2 on Ti-30Zr-5Mo alloy were investigated. The coatings were prepared using the sol-gel method and applied to the alloy substrates through dip-coating. The surface morphology and elemental composition of the coatings were analyzed using SEM/EDS and XRD techniques. Potentiodynamic polarization (PDS) and electrochemical impedance spectroscopy (EIS) were employed to assess the electrochemical behavior of the coatings under in-vitro conditions. Contact angle measurements were conducted to evaluate the wettability of the surfaces. Adhesion strength was measured using tensile testing in accordance with ISO 13779-2 standards. Bioactivity tests were performed by immersing the samples in simulated body fluid (SBF). The results demonstrate that the addition of Y2O3 and ZrO2 improves adhesion strength and corrosion potential, but introducing localized galvanic effects that increase the corrosion current density. Besides, the coatings maintained their structural integrity after the bioactivity tests, and promoted new apatite formation.

INFLUENCE OF GAS ENVIRONMENT OF SPRAYING ON THE PROPERTIES OF GAS-THERMAL METALLIZED COATINGS

This article is devoted to the study of the influence of the technological parameters of spraying, in particular the gaseous medium, on the physical and mechanical properties and corrosion resistance of gas-thermal metallization coatings. To protect the housings of submersible electric motors (PAD) in oil and gas wells, the method of electric arc metallization (EDM) has become widespread, due to the high level of physical and mechanical properties of the resulting gas-thermal metallization coating, high productivity and cost-effectiveness of the process, as well as the mobility of equipment. Despite the effectiveness of this method of protection, it does not exclude the occurrence of corrosion processes in the metal of the PAD body. In this regard, research aimed at increasing the operational life of the metallization coating is relevant and promising.The article considers the theoretical aspects of the influence of the technological parameters of the spraying process on the properties of the metallization coating. The effect of the sputtering gas medium on the physical and mechanical properties and corrosion resistance of metallization coatings has been experimentally investigated. Comparative tests and studies of gas-thermal metallization chromium-nickel coatings applied by the EDM method in an air environment and in an argon environment have been carried out. The main trends and features of the formation of metallization chromium-nickel coatings applied by the EDM method and the effect of the application mode, in particular the technological gas spraying medium on the microstructure studied on metallographic grinds using a scanning electron microscope with an attachment for energy dispersion analysis; microhardness determined by the Vickers method are determined; The wear resistance is determined by abrasive wear during friction against non-rigidly fixed abrasive particles and the corrosion resistance of the resulting coatings, determined by autoclave tests during exposure in a simulated environment containing corrosive components.The study of the influence of certain technological parameters of spraying of gas-thermal metallization coatings, including the gas medium, on the properties of the coatings obtained is a fairly promising task aimed at increasing the operational life of the metallization coating, which in the future will reduce the cases of premature failure of oilfield equipment.

Biocompatibility and corrosion resistance of drug coatings with different polymers for magnesium alloy cardiovascular stents

Recently, advances in enhancing corrosion properties through various techniques, and the clinical application of biodegradable cardiovascular stents made from magnesium (Mg) alloys face challenges to corrosion resistance, blood compatibility, and biocompatibility. Drug-eluting stents (DES) offer a solution to enhance the corrosion resistance of Mg alloys while simultaneously reducing the occurrence of restenosis. In this study, WE43 Mg alloy was pretreated using electropolishing technology, and different polymers (PEG and PLLA) were used as drug-polymer coatings for the Mg alloy. At the same time, PTX, an anticoagulant, was incorporated to achieve drug coating of different polymers on WE43 Mg alloy. The corrosion resistance of different polymer-drug coatings was assessed using a plasma solution. Furthermore, in vitro and in vivo tests were used to evaluate the blood biocompatibility of these coatings. The results indicated the PTX-PEG-coated WE43 Mg alloy exhibited the highest corrosion resistance and the most stable drug release profile among the tested coatings. Its hemolysis rate of 0.6 % was within the clinical requirements (<5 %). The incorporation of PEG prevents non-specific protein adsorption and nanoparticle aggregation, enhancing the surface hemocompatibility of WE43 Mg alloy. Therefore, the PTX-PEG coating shows promising potential for application in the development of drug-coated Mg alloy.

Eco-Friendly Waterborne Polyurethane Coating Modified with Ethylenediamine-Functionalized Graphene Oxide for Enhanced Anticorrosion Performance.

This study explores the potential of graphene oxide (GO) as an additive in waterborne polyurethane (WPU) resins to create eco-friendly coatings with enhanced anticorrosive properties. Traditionally, WPU's hydrophilic nature has limited its use in corrosion-resistant coatings. We investigate the impact of incorporating various GO concentrations (0.01, 0.1, and 1.3 wt%) and functionalizing GO with ethylenediamine (EDA) on the development of anticorrosive coatings for carbon steel. It was observed, by potentiodynamic polarization analysis in a 3.5% NaCl solution, that the low GO content in the WPU matrix significantly improved anticorrosion properties, with the 0.01 wt% GO-EDA formulation showing exceptional performance, high Ecorr (-117.82 mV), low icorr (3.70 × 10-9 A cm-2), and an inhibition corrosion efficiency (η) of 99.60%. Raman imaging mappings revealed that excessive GO content led to agglomeration, creating pathways for corrosive species. In UV/condensation tests, the 0.01 wt% GO-EDA coating exhibited the most promising results, with minimal corrosion products compared to pristine WPU. The large lateral dimensions of GO sheets and the cross-linking facilitated by EDA enhanced the interfacial properties and dispersion within the WPU matrix, resulting in superior barrier properties and anticorrosion performance. This advancement underscores the potential of GO-based coatings for environmentally friendly corrosion protection.

Effects of C Content on the Microstructure and Properties of CoCrFeNiTi0.5Mo0.5Cx High-Entropy Alloy Coatings by Laser Cladding

In order to deeply investigate the influence mechanism of different contents of non-metallic element C on the microstructure, microhardness, wear resistance and corrosion resistance of high-entropy alloy coatings. CoCrFeNiTi0.5Mo0.5Cx high-entropy alloy coating was prepared on the surface of AISI 1045 steel by laser cladding technology. The results show that the microstructure of CoCrFeNiTi0.5Mo0.5 without C addition consists of FCC phase, BCC phase, intermetallic compound phase and σ-phase structure, and the carbide phases (M7C3 and TiC) start to appear after the addition of C element. The microhardness of the coating increases and then decreases with the increase of C content, and the average hardness is the highest when x=0.03, 495.3HV0.5, which is 27.6% higher than that of C0. The abrasion resistance of the CoCrFeNiTi0.5Mo0.5Cx high-entropy alloy coatings is gradually increased and then decreased with the increase of C content, and the wear amount decreases from 0.0813 mm3 to 0.0514 mm3 , and the main frictional wear mechanisms are adhesive wear, abrasive wear and oxidative wear. With the increase of C content, the corrosion resistance of the coating is gradually improved and then reduced, when the C content is 0.03, the highest corrosion potential is -0.818V, the lowest corrosion current is 1.382E-4A/cm2, at this time, the passivation film on the surface of the coating is the most stable and dense, with the best corrosion resistance. The results of this paper provide a theoretical reference for the effect of adding non-metallic elements on the microstructure and properties of high-entropy alloy coatings.

Influence of TiO2-MWCNTs nanohybrid material on the corrosion resistance of epoxy low-zinc coatings

Aiming to improve the corrosion resistance of epoxy low-zinc coatings in marine environments, TiO2-MWCNTs nano-hybridized materials were prepared by sol-gel method in this study, and different contents of reinforcing phases were implanted as to improve the anticorrosive properties of epoxy low-zinc coatings. Characterization of the microscopic morphology, physical phase composition and chemical structure of the TiO2-MWCNTs materials demonstrated that the TiO2 hybridization was successful and the loading of TiO2 improved the dispersion of MWCNTs. To investigate the effect of the additive reinforcing phase on the mechanical and corrosion resistance of the coatings by characterizing the coating microscopic morphology, surface wettability, substrate adhesion, and impedance changes at different immersion times. The above results demonstrated that the epoxy composite coating had lower surface energy and 16% larger surface contact angle compared with the pure epoxy low-zinc coating; the 0.4wt.% TiO2-MWCNTs/epoxy composite coating had the highest adhesion of 6.52MPa. The electrochemical test results indicated that the TiO2-MWCNTs/epoxy low-zinc composite coating had the largest self-corrosion potential, the smallest self-corrosion current density of 4.538 μA/cm2, and the largest impedance of 242.3 KΩ/cm2. The addition of TiO2-MWCNTs reinforcing phase significantly extended the barrier protection time of the epoxy low zinc coating and maintained good corrosion resistance throughout the immersion cycle.

Effect of Electromagnetic Field Assistance on the Wear and Corrosion Resistance of Nickel-Based Coating by Laser Cladding

Offshore wind turbine generators usually demand higher requirements for key component materials because of the adverse working environment. Therefore, in this study, electromagnetic-assisted laser cladding technology was introduced to prepare the nickel-based composite coating on the Q345R matrix of wind turbine generator key component material. By means of Scanning Electron Microscope (SEM), X-ray diffraction (XRD), Energy Dispersive Spectrometer (EDS), the Vickers hardness tester, friction and wear tester, and electrochemical workstation, the effects of different magnetic field intensities on the macroscopic morphology, microstructure, phase composition, microhardness, wear resistance, and corrosion resistance of the coating were analyzed. The experimental results show that the addition of a magnetic field can effectively reduce the surface defects, improve the surface morphology, and not change the phase composition of the coating. With the increase in magnetic field intensity, the microstructure is gradually refined, and the average microhardness increases gradually, reaching a maximum of 944HV0.5 at 8 T. The wear resistance gradually increases with the increase in magnetic field intensity, especially when the magnetic field intensity reaches 12 T, the wear rate of the coating is reduced by 81.13%, and the corrosion current density is reduced by 43.7% compared with the coating without a magnetic field. The addition of an electromagnetic field can enhance the wear resistance and corrosion resistance of the nickel-based laser cladding layer.

Effect of in-situ NbC content on the microstructure and mechanical properties of Ni625 composite coating by laser cladding

To improve the mechanical properties of Ni625 coatings, different contents of Nb powder and Ni-coated graphite particles were added to Ni625 powder for in-situ generation of NbC particles. The effects of different NbC contents on the microstructure, hardness, wear resistance and corrosion resistance of Ni625 coatings were investigated. The results show that the highest XRD phase diffraction peaks of NbC in the coating are obtained with the addition of 15 % (Nb 9.9 %, Ni-coated graphite particles 5.1 %), and the coating exhibits a hardness of 441.9 HV, which is 1.53 times greater than that of the coating with the addition of 0 %. Furthermore, the wear coefficient (μ) of the coating is 0.4804, and the wear volume is 0.0042 mm3, representing a reduction of 23.5 % and 64.1 %, respectively, in comparison to the coating with 0 % additive. However, the coating with an addition of 20 % does not generate more NbC phase, and the hardness and wear resistance are not further improved. The coating with an addition of 10 % has the best corrosion resistance, with a corrosion current density of 2.1829E-10 A/cm2. Further additions do not result in an enhanced corrosion resistance of the coating. Therefore, appropriate amount of in-situ generation of NbC within the Ni625 coating during the laser cladding process can effectively enhance the mechanical properties of the Ni625 coating.

Effect of ZrC particle on microstructure and corrosion behavior of CoCrNi medium-entropy alloy fabricated by powder plasma arc cladding

Medium-entropy alloys (MEAs) show significant potential as corrosion-resistant coatings. However, their industrial applications are limited by fabrication challenges and low efficiency. This study synthesized CoCrNi(ZrC)x MEA coatings using powder plasma arc cladding (PPAC) technology. The CoCrNi(ZrC)x MEAs consist of columnar and equiaxed grains. Incorporating ZrC refines the grain structure, achieving maximum refinement at x = 3. This refinement enhances the coating hardness by approximately 40% (from 165 ± 3.36 to 229 ± 4.83 HV0.1), mainly due to Hall-Petch strengthening, solid solution effects, and grain boundary and dispersion strengthening. In 3.5wt% NaCl solution, corrosion resistance was notably improved, as evidenced by a substantial decline in corrosion pits and an 81% (from 4.52 to 0.86 μA/cm²) reduction in icoor. This enhancement is primarily due to ZrC reducing the exposed surface area of the coating and providing protection through localized Cr segregation at anodic sites. This study is the first to introduce ZrC ceramic particles into CoCrNi MEAs, advancing the development of corrosion-resistant coatings.