Corrosion Resistance Of Coatings Research Articles

Effect of solution temperature on the microstructure and properties of ceramic coating on the surface of 2024 aluminum alloy

This study investigates the influence of the 2024 aluminum alloy was treated with solution before ceramic treatment on the microstructure and characteristics of ceramic coatings applied to 2024 aluminum alloy substrates. The microhardness, corrosion resistance, and microstructural properties of these ceramic coatings were assessed using a microhardness tester, an electrochemical workstation, and a scanning electron microscope. The findings indicate that pre-treatment involving solution treatment significantly enhances the hardness and corrosion resistance of 2024 aluminum alloy ceramic coatings. Notably, when the solution temperature was maintained at 460 °C, the most rapid decrease in current density was observed during the ceramization process, resulting in the attainment of the lowest final stable current density. This particular condition yielded ceramic coatings with optimal hardness and corrosion resistance, with hardness exhibiting a remarkable increase of 48.9 HV, self-corrosion potential rising by 0.207 V, and polarization resistance surging by 5310.7 Ω. Moreover, the surface of the ceramic coating displayed remarkable smoothness and was devoid of discernible defects such as cracks or looseness. In light of these findings, it can be concluded that the optimum solution temperature for achieving these desirable properties is 460 °C. This conclusion is derived from a comprehensive analysis encompassing both the morphology and corrosion resistance of ceramic coatings.

Corrosion Resistance of Magnesium Ammonium Phosphate Cement-Based Coatings Modified by Calcium Sulfoaluminate Cement on Carbon Steel in a Saline Medium

Corrosion Resistance of Magnesium Ammonium Phosphate Cement-Based Coatings Modified by Calcium Sulfoaluminate Cement on Carbon Steel in a Saline Medium

Microstructure Evolution and Molten Salt Corrosion Resistance Dependent on Pre-Oxidation Treatment of NiAl Coatings

The chloride-infused molten salt shows the most potential as the medium for the upcoming generation of concentrated solar power system. However, the molten salt put for ward higher corrosion resistance demand on the critical components of concentrated solar power system. The application of NiAl coating proves to be a highly efficient method for preventing corrosion. In this paper, the microstructure, adhesion, and corrosion resistance of NiAl coatings on 310S stainless steel with/without pre-oxidation treatment were studied. The coating predominantly consisted of β-NiAl phase nanocrystals with an Al content of 41.0 at.%. Continuous α-Al2O3 oxide film was formed and no obvious cracks were observed after pre-oxidation. The adhesion strength of NiAl coating was increased by about 70% to 40.0 N through pre-oxidation. Importantly, the corrosion results of NiAl coatings by pre-oxidation treatment in the mixed salt of NaCl/MgCl2/KCl at 1073.15 K for 10 h showed no obvious diffusion of molten salt elements into the coatings. Compared to 310S stainless steel, the pre-oxidized coating sample exhibited a significant reduction of 50.2% in corrosion mass loss. The pre-oxidation of the NiAl coating creates an Al2O3 oxidation layer that effectively blocks corrosion, offering a new method for protecting stainless steels in concentrated solar power system plants.

Anticorrosion and adhesion performance of a monolayer and double layer silane-epoxy coating systems applied on carbon steel

Carbon steel is one of the widely used metallic material, although its limited corrosion resistance. To improve its anti-corrosion performance, organic coatings such as epoxy have been an excellent option due to their barrier mechanism. Nevertheless, the elevated brittleness and porosity observed in this type of coating, coupled with the weak bonding interface between epoxy and carbon steel, significantly hampered their protective capabilities. The organofunctional silanes are candidates to be used as pre-treatment between epoxy coating and carbon steel interface because of their good corrosion resistance but as a limitation they can present small pores and microcracks.Therefore, the anticorrosive and mechanical properties of silane films can be adapted and further improved by strengthening the coatings through some modifications, such as the incorporation of green corrosion inhibitors into the film, reducing the access of aggressive species to the metal. In this context, the objective of this research is to evaluate the adhesion and anticorrosive properties of an epoxy-based organic coating pre-treated with a silane film obtained by tetraethoxysilane (TEOS) with γ-glycidoxypropyltrimethoxysilane (GPTMS) modified with the garlic peel powder as a corrosion inhibitor (Allium sativum L.). The investigation of the surface features as morphology and the corrosion resistance of the silane-epoxy coatings were studied by scanning electron microscope (SEM) and electrochemical characterization techniques, such as, electrochemical impedance spectroscopy (EIS), linear and potentiodynamic polarization. Also, the coating adherence was evaluated by pull-off tests. The results of the EIS showed that all samples coated with silane+ epoxy coating have better anticorrosion performance than the sample coated with just epoxy painting. Besides, SEM images showed that the silane film improved the cohesion between substrate and coating system, with the clear appearance of delamination in the system silane free. In general, the results of these different techniques indicate that the film modified with the natural inhibitor has improved anticorrosive properties compared to the film without silane or natural green inhibitors.

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

Abstract 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.

Exploring the Impact of Potential, Ammonium Fluoride Concentration, and Anodization Time on the Structure, Surface Characteristics, and Corrosion Resistance of Nanotubular Titanium Oxide Coatings on Biomedical Alloy Ti-6Al-4V ELI

The current research delves into assessing the impact of applied potential, ammonium fluoride concentration, and anodization duration on the structural, phase compositional, microhardness, and surface roughness attributes of nanotubular titanium oxide coatings on anodized Ti-6Al-4V ELI. A meticulous experimental design was executed to systematically investigate the varied effects of these factors. Scanning electron microscopy (SEM) unveiled the presence of well-defined titania nanotubes on the surfaces of the anodized specimens. X-ray diffraction (XRD) analysis discerned the composition of the nanotubular oxide layer, revealing the presence of both anatase and a mixture of anatase and rutile phases contingent upon the anodization parameters. Notably, surface microhardness, surface roughness, and corrosion resistance manifested noticeable variations in response to alterations in applied voltage, NH4F concentration, and anodization duration within the designated experimental ranges.

Assessment of results of verification tests for corrosion-resistant coatings for use in pipeline transport of oil and oil products

Assessment of results of verification tests for corrosion-resistant coatings for use in pipeline transport of oil and oil products

Corrosion resistance and conductivity of CrN, CrAlN, and CrTiN coatings applied to bipolar plates for proton exchange membrane fuel cells

In order to improve the corrosion resistance and conductivity of 316L stainless steel bipolar plates used for proton exchange membrane fuel cells, three Cr-containing nitride coatings were deposited on 316L stainless steel by multiarc ion plating. First, the microstructure, composition, and contact angle of the three coatings were systematically investigated. Then, electrochemical impedance spectroscopy, potentiodynamic polarization, potentiostatic polarization (PSP), and interfacial contact resistance (ICR) of the three coatings were also fully examined. The results revealed that CrN coating has the highest contact angle of 98.26°, indicating its superior hydrophobicity. Additionally, CrN coating performed the best corrosion resistance with the highest corrosion potential of 0.31 V, the lowest corrosion current density of 2.28 × 10−7 A cm−2, and the largest resistance. Furthermore, CrN coating showed the lowest current density during PSP tests and the smallest ICR value after corrosion. The superior corrosion resistance of CrN coating is mainly attributed to its decreased pore density caused by vacancylike defects and its uniform structure. This article provided evidence for the potential application of CrN coating to bipolar plates.

Influence of Different Copper Feedstock Powders on the Microstructure and Corrosion Resistance of Coatings Prepared by Cold Gas Spray

Influence of Different Copper Feedstock Powders on the Microstructure and Corrosion Resistance of Coatings Prepared by Cold Gas Spray

Binary potential loop electrodeposition and corrosion resistance of Cr coatings

Binary potential loop electrodeposition and corrosion resistance of Cr coatings

Assessment of HVAF thermally sprayed coatings: Unraveling microstructural, electrochemical, and tribological performance using glass former Fe-Cr-Mo-Nb-B feedstock powder

In this paper the microstructural features of the glass former Fe68Cr8Mo4Nb4B16 coatings are unveiled and related to their electrochemical and tribological responses. The coating was mostly glassy with some embedded borides (M3B2, M2B-tetragonal; M being the metallic elements of the alloy) and ferrite. The tribological behavior of the HVAF coated sample, characterized by a thickness of about 200 µm, ∼6% porosity and a Vickers hardness of 357 HV0.5, was assessed in a sphere-on-plate configuration, revealing a specific wear rate of approximately 5 ×10−4 mm3∙N−1m−1. The wear mechanism was dominated by delamination caused by fragile intersplats. The corrosion resistance of HVAF coatings was evaluated in 0.6 M NaCl solution and compared with the results obtained for the crystalline Fe68Cr8Mo4Nb4B16 ingot, produced by melting in an induction furnace, and for the AISI 1020 steel substrate. The HVAF coating showed satisfactory corrosion resistance compared to the carbon steel substrate and the crystalline ingot, with the highest corrosion potential, Ecorr, values (−533 mVSCE) and the lowest corrosion current density, icorr, (10−6 A∙cm−2) followed by a clear passivation window upon anodic polarization in 0.6 M NaCl solution. Evaluations of HVAF coating showed a higher glassy content compared to the gas-atomized feedstock powders. This suggests that during spraying, certain particles were molten and experienced cooling rates adequate to inhibit crystallization, resulting in the freezing of the supercooled liquid. This phenomenon contributes to the good corrosion resistance observed in the present work and offers an opportunity to enhance the electrochemical behavior of HVAF coatings.

Effect of WC-10Co-4Cr Reinforcement Amount on Wear and Corrosion Resistance of Fe-Based Amorphous Coatings

Effect of WC-10Co-4Cr Reinforcement Amount on Wear and Corrosion Resistance of Fe-Based Amorphous Coatings

Study on the corrosion performance of supersonic atmospheric plasma sprayed Cr3C2-NiCr coatings

Purpose Due to the harsh underground environment in coal mining, the surface of hydraulic support columns corrodes severely, resulting in significant economic losses. Therefore, a highly corrosion-resistant coatings is needed to extend the service life of the columns. Design/methodology/approach This study aims to compare the corrosion resistance of ST-Cr3C2-NiCr (sealed treatment Cr3C2-NiCr) coatings with industrially applied chromium plating. The corrosion failure mechanism of the coatings was investigated. Findings The results demonstrated that the ST-Cr3C2-NiCr coatings exhibited excellent corrosion resistance. After sealing treatment, the corrosion potential of Cr3C2-NiCr coatings was −0.215 V, and the corrosion current density of Cr3C2-NiCr coatings was lower than that of the plated parts. Practical implications ST-Cr3C2-NiCr coatings prepared by supersonic atmospheric plasma spraying could provide excellent corrosion resistance in the coal industry. Originality/value The low porosity and the presence of the NiCr phase were crucial factors contributing to the preferable corrosion resistance exhibited by the ST-Cr3C2-NiCr coatings. The corrosive process of the coatings involved layer-by-layer delamination of surface oxide film, sub-surface pitting, formation and degradation of sub-surface passive film, as well as severe block-like delamination.

Glycine-Ti3C2Tx Hybrid Material Improves the Electrochemical Corrosion Resistance of a Water-Borne Epoxy Coating.

Improving the dispersibility and compatibility of nanomaterials in water-borne epoxy resins is an important means to improve the protection ability and corrosion resistance of coatings. In this study, glycine-functionalized Ti3C2Tx (GT) was used to prepare an epoxy composite coating. The results of Fourier transform infrared spectroscopy and X-ray diffraction showed that glycine was successfully modified. The scanning electron microscopy and transmission electron microscopy results showed that the aggregation of Ti3C2Tx was alleviated. Electrochemical impedance spectroscopy test results show that, after 60 days of immersion, GT coating still shows the best protection performance, and the composite coating |Z|f = 0.01 Hz is 3 orders of magnitude higher than that of the pure epoxy coating. This is mainly because, after adding glycine, the -COOH group on the surface of glycine binds to the -OH group on the surface of Ti3C2Tx, improving the aggregation of Ti3C2Tx itself. At the same time, the -NH group of glycine can also participate in the curing reaction of epoxy resin to strengthen the bonding strength between the coating and the metal. The good dispersion of GT in epoxy resin makes it fill the pores and holes left by epoxy resin curing and strengthen the corrosion resistance. The easy availability and green properties of glycine provide a simple and environmentally friendly method for the modification of Ti3C2Tx.

Research on cobalt-molybdic sulfide composite coatings deposited by magnetic jet electrodeposition under different magnetic field intensities

Co-MoS2 composite coatings were deposited by the magnetic jet electrodeposition under different magnetic field intensities. The growth orientation and deposition mechanism of Co-MoS2 composite coatings under magnetic jet electrodeposition were analyzed based on the weak adsorption theory of nanocomposite co-deposition. Research showed that the coating topography changed from a blade-like structure to a cellular structure, and the cellular structure became a granular protrusion structure with increase of the magnetic field intensity. Compared with Co-MoS2 composite coating in jet electrodeposition, the orientation of Co shifted from (110) to (101) as the magnetic field intensity increased in magnetic jet electrodeposition. The adhesion, microhardness, adhesion, corrosion and wear resistance of the composite coatings were enhanced, which was attributed to the influence of the magnetic field on the growth orientation of the composite coating and the coordinated lubrication effect in the Co-MoS2 composite coating.

Effect of annealing treatment of hot-rolled AZ31 magnesium alloy on properties and stress corrosion resistance of MAO coatings

PurposeThis study aims to study the formation mechanism of micro-arc oxidation (MAO) coating on AZ31 magnesium alloy and how the annealing process affects its corrosion resistance.Design/methodology/approachThis study involved immersion experiments, electrochemical experiments and slow strain rate tensile experiments, along with scanning electron microscopy, optical microscopy observation and X-ray diffraction analysis.FindingsThe findings suggest that annealing treatment can refine the grain size of AZ31 magnesium alloy to an average of 6.9 µm at 300°C. The change in grain size leads to a change in conductivity, which affects the performance of MAO coatings. The MAO coating obtained by annealing the substrate at 300°C has smaller pores and porosity, resulting in better adhesion and wear resistance.Originality/valueThe coating acts as a barrier to prevent corrosive substances from entering the substrate. However, the smaller pores and porosity reduce the channels for the corrosive solution to pass through the coating. When the coating cracks or falls off, the corrosive medium and substrate come into direct contact. Smaller and uniform grains have better corrosion resistance.

In Situ Polymerized Self-Healing Microcapsules as Multifunctional Fillers toward Phosphate Ceramic Coatings.

The protective efficacy of chemically bonded phosphate ceramic coatings (CBPC) is notably diminished owing to the presence of micropores and inadequate self-healing capacity in prolonged corrosive environments. Consequently, it is imperative to augment the corrosion and wear resistance of phosphate ceramic coatings while imbuing them with self-healing capabilities. In this work, a novel self-healing phosphate ceramic coating (MC-PTx@CBPC, x = 0.5, 1.0, 1.5) is designed by urea-formaldehyde (UF) in situ polymerization of nanoscale microcapsules encapsulated with 1H,1H,2H,2H-perfluorodecyltriethoxysilane (PFDTES) and evaluated in detail for corrosion and wear resistance. The corrosion inhibition efficiencies of all formulated MC-PTx@CBPC (x = 0.5, 1.0, 1.5) coatings exceed 90%, with the impedance modulus at the lowest frequency (|Z|f=0.01) showing enhancements of 1-2 orders of magnitude compared to pure CBPC. Moreover, the self-healing function becomes active during prolonged immersion. This can be primarily ascribed to the formation of a unique micronanostructure facilitated by nanoscale microcapsules and micrometer-sized alumina ceramics, bonded via the AlPO4 phase. This structure enhances both the hydrophobicity and the bonding strength of the coating. Specifically, following prolonged immersion, the encapsulated PFDTES is liberated from the microcapsules, undergoing hydrolysis and subsequent polymerization upon contact with the electrolyte to form a protective thin film. This film efficiently obstructs the ingress of corrosive agents. Furthermore, the special micronanostructure enhances the hardness of the coating and the releasing PFDTES can form a lubricating film at the interface of abrasion, thus reducing the wear rate and friction coefficient of the MC-PTx@CBPC (x = 0.5, 1.0, 1.5). Therefore, MC-PTx@CBPC (x = 0.5, 1.0, 1.5) possesses excellent corrosion protection, tribological properties, and self-healing capabilities, which provide thought-provoking ideas for phosphate ceramic coatings to protect metals in harsh environments.

In Situ Construction of Fluorescent and Corrosion Resistant Coating by Plasma Electrolytic Oxidation on Magnesium Alloy

In Situ Construction of Fluorescent and Corrosion Resistant Coating by Plasma Electrolytic Oxidation on Magnesium Alloy

One-step hydrothermal preparation of corrosion-resistant coatings with microsphere structure

Rapid corrosion rate is limiting the engineering application of magnesium alloys. In this paper, an attempt was made to produce a corrosion resistant coating on the surface of AZ91D magnesium alloy using hydrothermal method. The coating surface is covered with microspheres and has a dense structure, which effectively isolates the contact between the outside world and the substrate. The corrosion potential(E) raised from −1.57 V to −0.45 V compared to the bare sample. The corrosion current density and corrosion rate of the coating can be reduced by 6 orders of magnitude, and the polarization resistance raised by 6 orders of magnitude. The thickness of the coating is 45.4 μm at the moment, with a minimum of defects on the surface, resulting in excellent corrosion resistance in the immersion test. The coating also has good adhesion strength at 4B, which can expand the application range of magnesium alloy in corrosive environments.

REVIEW: MATERIALS FOR IMPREGNATION OF POROUS METALLIZATION THERMAL SPRAYED ANTICORROSIVE COATINGS OF SUBMERSIBLEOILFIELD EQUIPMENT. Part 1

Submersible oilfield equipment undergoes aggressive corrosive effects of petroleum fluid, abrasive effects of mechanical impurities during operation, and also operates at elevated temperatures in the bottom. The most effective way to protect the outer surface of oilfield equipment is the use of metallization thermal sprayed coatings, and therefore the application of thermal spraying technology is becoming more and more in demand.However, the formation of a coating structure from many particles of molten material, due to their spraying, incomplete melting and loose packaging, leads to the formation of porosity, and porosity is one of the main disadvantages of thermal sprayed coatings. To eliminate this disadvantage, it is possible to use impregnation of porous coatings with various compositions, in which case the coating becomes composite. Depending on the operating environment, temperature conditions and operating conditions, metal, organic and inorganic impregnating compositions are used,but their use in the oil environment has been little studied, therefore the development of composite impregnated coatings is relevant for the protection of submersible oilfield equipment. The article highlights the influence of technological modes of its application on the porosity of thermal sprayed coating and the quality of substrate surface preparation. The main methods of sealing the porosity of thermal sprayed coatings by impregnation are described. The mechanism of impregnation (infiltration) of porous coatings, used methods of application and their classification are described, the determining role of wetting the coating with an impregnating material is emphasized. The effect of the rough surface of a thermal sprayed coating is shown, which consists in enhancing the wetting properties of the impregnating composition, the influence of roughness on the formation of adhesive bonds between the coating and the impregnating composition.The review presents traditional impregnating materials used in industry and their application modes.The application of metal and non-polymer inorganic impregnating compounds, represented mainly by salts of inorganic acids (nitrates, phosphates, silicates), is described. Specific test results are presented, including for the corrosion and abrasive resistance of thermal sprayed coatings after the application of impregnating compounds.