Corrosive Media Research Articles

Assessment of Oil Paints for Corrosion Protection of Reinforcing Steel Bars in Concrete

Corrosion becomes a threat to reinforced concrete structural integrity during the service life of the structural member. This situation has become a global concern because of the economic and safety implications. Hence, many corrosion inhibition techniques including coating with materials (organic and inorganic) were used to prevent its devastating effects. The present study used three oil paint brands (mat, red-oxide and gloss Leyland oil paints in Ghana) to variedly coat reinforcing steel bars to ascertain their corrosion protection capacity in concrete. There were zero, one, two and three paint coats of average film thickness, 72 µm, 129 µm and 220 µm respectively explored. An Electrochemical process involved simulated concrete pore solution made of 10% sodium chloride (NaCl) in distilled water with three electrode systems to represent a corrosion medium was used to determine corrosion protection capacity of the paints. The results indicate over 90% corrosion resistance of the paints used. Comparing the corrosion rates of the coated and uncoated reinforcing steel bars, while it would take a one coat steel bar 342.5 years and 237 years respectively for spraying and manual brushing modes to reduce in diameter by 0.616mm, it would take only one year for an uncoated steel bar to reduce by this same 0.616mm. The protection capacity proved better with increasing coats on all corrosion variables for the selected paints used. The implication is that the selected oil paint brands are capable of protecting reinforcing steel bars in concrete against corrosion and therefore recommended for application to reduce maintenance cost. Statistically, no significant difference existed between coating mode, number of coatings, paint type and steel type on the corrosion variables for the coated steel bars. However, a further study about the durability of the coating in the concrete during its service time is recommended.

EFFECT OF HEAT TREATMENT OVER THE MECHANICAL PROPERTIES AND THE RESISTANCE TO CORROSION OF THE TERNARY Cu-Al-Ag ALLOY

Abstract In the present work, the manufacture of a Cu-9Al-3Ag alloy was carried out easily through a green molding process. After dimensioning and slitting, the alloy samples were subjected to quenching, normalizing, and annealing heat treatments, to exert phase transformations that would, in return, aid into clarifying the influence of the phases present on the mechanical properties, such as hardness, as well as the behavior when exposed to a commonly known mildly corrosive media such as NaCl. The results obtained reveal an increase in hardness (assessed through either HRB) and (microhardness HV) in the quenched and annealed sample, as well as better corrosion resistance. The characterization was carried out through optical microscopy, Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), potentiodynamic polarization tests and electrochemical impedance spectroscopy.

EVALUATION OF PHYSICAL AND MECHANICAL PROPERTIES OF THERMOPLASTIC COATING BASED ON POLYOLEFINS

The article presents an analysis of the results of physical and mechanical tests of thermoplastic coating samples after exposure to corrosive solutions. To obtain a thermoplastic coating, powder polymer paint of two original compositions was used. According to the results of the experiments conducted to study the change in the strength of the thermoplastic coating material based on polyolefins after its exposure to corrosive solutions, it is received that the decrease in the tensile strength is no more than 5 %. This is quite a good result, and is a background for their use on the metal surface of oil and gas equipment operating in corrosive mediums.

ENHANCING SURFACE CHARACTERISTICS OF AA2024-T3 AIRCRAFT ALLOY THROUGH SYNERGISTIC ANODIZATION AND CERIUM CONVERSION COATING. PART I: PERFORMANCE IN MODEL CORROSIVE MEDIUM

The present study is devoted to the monitoring of the performance of AA2024-T3 specimens, after the formation of Anodic Aluminum Oxide (AAO) layer and/or deposition of a Ceruim Conversion Coating (CeCC), obtained at 20°C and 50°C, respectively. Although both methods are well described in the literature, there is no sufficient information regarding the effect of their combination on their behaviour in corrosive media. The performance of the respective specimens was elucidated after 24 h of exposure to 3.5 % NaCl model corrosive medium (MCM) by means of Electrochemical Impedance Spectroscopy (EIS) and acquisition of Potentiodynamic Scanning (PDS) curves. Since the combined AAO/CeCC coating primers revealed superior barrier properties, the respective specimens weresubjected to long-term corrosion tests of up to 672 h of exposure to the MCM to evaluate their durability. The results revealed the synergistic effect of the combination of the surface treatment procedures on effective corrosion mitigation.

Research on the multi environmental corrosion characteristics and mechanism of B4C doped Fe–Cr–Ni composite coating produced by laser cladding

Different Fe–Cr–Ni composite coatings doped with B4C were produced on the surface of Cr12MoV steel by laser cladding. Special attention was paid to the effects of B4C content on the phase composition, microstructure, and corrosion resistance of the cladded layers. The results indicated that the Fe–Cr–Ni composite coating was primarily composed of α-(Fe, Cr) and γ-(Ni–Cr–Fe) solid-solution phases, as well as Fe2B, M7C3, Fe3Si and M23C6 phases. Once the B4C content increased to 10 wt%, the microstructure of the cladding layer became coarse and exhibited the prominent carbide agglomeration. The composite coatings with different B4C contents exhibited superior corrosion resistance compared to the pure substrate in both 3.5 wt% NaCl and 1 mol/L HCl solutions. Furthermore, as the B4C content increased, the corrosion resistance of the coating initially increased and then declined. In particular, the Fe–Cr–Ni composite coating with an 8 wt% B4C content experienced the pronounced passivation in the corrosive media and possessed the optimal corrosion resistance due to the synergistic effect of the passive film and carbide barrier layer.

Influence of Si-addition on tribological and corrosion properties of Ta-Si-C coatings

Ta-Si-C coatings with Si content varying from 2.7 to 30.8 at.% were synthesized by magnetron co-sputtering. Their microstructure, tribological properties and corrosion performance were investigated. The coatings exhibited two distinct structural forms: a Ta(C, Si) solid solution for the lower silicon contents (2.7 and 5.6 at.% Si) and a Ta(C, Si)/a-C:Si nanocomposite for higher Si content (13.7, 20.8 and 30.8 at.% Si). Notably, the Ta(C, Si) solid solution at 5.6 at.% Si demonstrated the highest hardness of 44±2.7 GPa, resulting from the solid solution strengthening. Furthermore, this solid solution also demonstrated the lowest wear rate (1.21×10-6 mm3N-1m-1), due to its superior hardness and H3/E2 ratio. Additionally, the coating with 5.6 at.% Si displayed the most outstanding corrosion resistance, attributed to its higher crystalline quality and denser structure, which effectively prevented the permeation of corrosive media through the coating to the substrate.

Impressive reinforcement on the anti-corrosion ability of the commercial fluorocarbon paint via an amino groups modified graphene

The interaction with the matrix and the dispersion within the matrix hinder the realization of graphene's potential as an anti-corrosive filler. Herein, a -NH2 modified graphene-based filler (PS-PVP@NH2-rGO) was designed to simultaneously address these issues in the fluorocarbon resin (FEVE) coating. Reinforing FEVE coating with PS-PVP@NH2-rGO, the wear rate and the lowest-frequency impedance modulus after a 7-day immersion were found to be 0.35 times and 177.3 times those of FEVE coating respectively. Ultraviolet-Visible spectra confirmed the excellent dispersibility of PS-PVP@NH2-rGO. The designed differential scanning calorimeter experiment demonstrated the close interaction between PS-PVP@NH2-rGO and the FEVE matrix. Due to this close interaction, PS-PVP@NH2-rGO exhibited a high degree of dispersion within the FEVE matrix rather than self-aggregation, then concentrated the stress outside, absorbed energy produced during the friction process, and enhanced the coating's wear resistance. A complicated “labyrinth” was also created by the fillers. With chemical interactions, the fillers and the surrounding FEVE matrix formed an integrated whole, making the “obstacles” created by the fillers more significant. Consequently, the strong barrier effect resulted in superior anti-corrosion performances of PS-PVP@NH2-rGO/FEVE coating. Introducing -NH2 groups in was proven to effectively complete the coating, improve coating's quality and barrier effect, and finally prevent corrosive media. This study aims to provide design ideas and theoretical supports for high-performance heavy-duty anti-corrosive coatings.

Poly aryletherketone chemically modified multi-walled carbon nanotubes/poly etheretherketone electromagnetic interference shielding foam suitable for high temperature and strong corrosive media

Poly aryletherketone chemically modified multi-walled carbon nanotubes/poly etheretherketone (PAEK-m-CNTs/PEEK) electromagnetic interference (EMI) shielding foams were fabricated using supercritical carbon dioxide (Sc-CO2) foaming technique saturated near-melting point (Tm). The percolation thresholds for conductivity and EMI shielding of PAEK-m-CNTs/PEEK foams were both significantly reduced by the presence of the porous structure, reaching to 0.0457 vol% and 0.123 vol%, respectively. These reductions were observed to be 87.72% and 75.20% of those of PAEK-m-CNTs/PEEK composites. This could be attributed to the heterogeneous nucleation of PAEK-m-CNTs, which are uniformly dispersed in PEEK, in addition to the Sc-CO2 foaming technique saturated near Tm. By comparison, it could be observed that the specific total electromagnetic shield effectiveness (SSETotal) of PAEK-m-CNTs/PEEK foam with a filler content of 0.440 vol% was 687.9% higher than that of PAEK-m-CNTs/PEEK composite with a filler content of 0.496 vol%. Moreover, the introduction of the porous structure transformed the electromagnetic shielding material from reflective to absorptive. In addition, PAEK-m-CNTs/PEEK foams demonstrated the capacity to maintain stable performance even in high temperatures of up to 315 °C and in the presence of strong corrosive media.

Constructing dual-ligand Ce-MOF on graphene oxide modified with polydopamine endowing polyurethane coating with long-term smart anti-corrosion and mechanical robustness

Traditional mono-functional anti-corrosion coatings are unable to meet the long-term corrosion resistance requirements of metal materials, therefore developing multifunctional anti-corrosion coatings have broad application prospects. In this work, long-lasting anti-corrosion coatings with superhydrophobic and self-healing properties were successfully prepared by in-situ growth of dual-ligand cerium-based metal–organic framework (Ce-MOF) on the surface of graphene oxide (GO), followed by chemical modification with polydopamine (PDA), resulting in 5B level of adhesion and excellent mechanical robustness. The superhydrophobic surface, as the external armor of the coating, can effectively block the penetrating path of corrosive media. Meanwhile, the MOF structure formed by the coordination of 2-mercaptobenzimidazole (2-M) with cerium ions endows the coating with smart self-healing properties and long-lasting corrosion resistance. Electrochemical tests showed that the low-frequency impedance modulus value of the superhydrophobic coating still reached 3.82 × 108 Ω cm2 after 30 days salt immersion. Due to the formation of protective films and insoluble precipitates at the defect site by 2-M and cerium ions, the scratches on the coating were significantly reduced after 40 days salt spray experiment, demonstrating the self-healing ability of the coating. This multifunctional anti-corrosion coating provides a new approach for preparing coatings with long-term effective corrosion resistance.

Aromatic Metal Corrosion Inhibitors

Molecular inhibitors added to the corrosive medium attacking metallic materials are a well-established way of combating corrosion. The inhibitive action proceeds via adsorption of the inhibitor on the surface to be protected. Aromatic building blocks in the inhibitor play a major role in its protective action, and further details like substituents, heteroatoms, and molecular geometry contribute. An overview focused on aromatic inhibitors is provided, aiming at the identification of particularly promising inhibitors and their mode of action. Directions for further research and development are pointed out in the conclusion.

Synthesis and evaluation of anticorrosive properties of cationic benzenesulphonamide surfactants on carbon steel under sweet conditions: Empirical and computational investigations

In this study, three cationic surfactants bearing a benzenesulphonamide moiety as corrosion inhibitors (PSA-8, PSA-10, PSA-12) were synthesized using a straightforward two-step process. Their chemical structures were investigated via spectroscopic tools such as 1H and 13C NMR. The surface activity of as-prepared cationic surfactants was examined. To evaluate the effectiveness of these surfactants in the corrosion protection of carbon steel pipelines (C1018-steel) in a CO2-3.5 % NaCl environment, several techniques were used, including electrochemical measurements (potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) techniques), surface morphology examinations applying X-ray photoelectron spectroscopy (XPS) analysis, density functional theory (DFT) calculations, and Monte Carlo (MC) simulations. Notably, the corrosion efficiency of the PSA surfactants was compared with previously reported cationic surfactants containing the CN group (i.e., an electron-withdrawing group). The experimental results showed excellent inhibition performance of the PSA surfactants, with inhibition capacities ranging from 92.8 % to 97.0 %. This indicates that removing the CN group has significantly enhanced the corrosion inhibition efficiency, shedding light on the electronic effectas well as the adsorption and corrosion processes. Analysis of the Tafel data indicated that these surfactants functioned as mixed-type inhibitors and followed the Langmuir isotherm model in their adsorption on the carbon steel interface and the corrosive medium. XPS analysis confirmed the establishment of a shielding barrier at the interface of the carbon steel. DFT calculations were employed to establish the correlations between theoretical parameters and experimental observations, thereby validating their connection. Moreover, the employment of MC simulations validated the efficacy of the adsorption properties of the synthesized surfactants on the iron (110) surface. Ultimately, this investigation provides substantial insights into the development and formulation of bioactive inhibitors characterized by their potent inhibitory effectiveness.

Experimental Study on the Mechanical Properties of Squat RC Shear Walls with Corrosion Along the Base

In corrosive environments containing chloride and sulfate, the corrosion of steel bars is common along the base of squat RC shear walls (SRCSW) due to problems such as construction quality, concrete stress concentration, local defects, and accumulation of water and corrosive media. In this paper, three SRCSWs are designed and constructed and their mechanical properties assessed. One side of each SRCSW was exposed to a corrosive environment for 70 days, while the other side was subject to the same conditions over different corrosion times (i.e., 0 day, 42 days, and 70 days). Then, the corrosion-induced cracking process, the mechanical properties of SRCSWs corroded along the base, the relationship between the mass loss of total steel bars (MLTSB) in the corroded area and the wall mechanical properties, and the relationship between the average width of corrosion-induced cracks (CICs) and the wall mechanical properties were studied through an accelerated corrosion test and a loading failure test. The results indicate that the area of corrosion-induced cracking on SRCSWs increased with the corrosion time, and the cracking area on the different SRCSWs was approximately identical when the SRCSWs were exposed to the same corrosion time. When the degree of corrosion was different, the loading failure characteristics of the SRCSWs were obviously different, but the failure mode always corresponded to shear failure. The load–displacement curves of the SRCSWs with different degrees of corrosion along the base basically coincided and were linear when the loading was in the elastic stage. Compared to SW-1, the peak load of SW-2 decreased by 4.0%, but that of SW-3 increased by 2.7%. Compared to SW-1, the yield loads of SW-2 and SW-3 decreased by 22.4% and 11.8%, respectively. When the MLTSB increased from 13.05% to 16.71%, the crack, yield, and peak loads of the SRCSWs corroded along the base decreased by 8.8%, 22.4%, and 6.8%, respectively. The cracking, yield, and peak loads of the SRCSWs corroded along the base decreased linearly with the increase in MLTSB and the average width of the CICs, and the corresponding fitting relations were established. The results of this study can serve as a reference for the durability design of SRCSWs in corrosive environments.

Cellular Automata-Based Experimental Study on the Evolution of Corrosion Damage in Bridge Cable Steel Wire

Cable-stayed bridges have become the preferred bridge type for large-span bridges due to their unique advantages, and the long-term performance of the cable under the extreme conditions has been facing great challenges. An accelerated corrosion test was carried out using in-service cable, and the evolution model of the etch pit was established based on cellular automata to study the evolution law of corrosion damage to steel wire. This study showed that with the increase in the number of dry-wet cycles in the electrified accelerated corrosion, the macro- and micromorphology of the steel wire showed more serious corrosion damage, the tensile strength decreased, the ductility index decreased, and the tensile strength of the steel wire after corrosion decreased by nearly 5%; the geometric dimension of the steel wire etch pits all met a right-skewed distribution with a broader range of etch pit depth, mainly consisting of shallow spherical etch pits and deep ellipsoidal etch pits. The length, width, and depth sizes were mainly distributed in the range of 0.005 mm to 0.015 mm, 0.005 mm to 0.02 mm, and 0 mm to 0.04 mm; at the early stage of corrosion, the etch pits were first developed along the longitudinal direction. As the corrosion process progressed, the iron matrix participated in the electrochemical reaction, leading to the rapid expansion of the etch pits’ dimensions. The stress concentration effect at the bottom of the etch pit caused the maximum stress to approach 1800 MPa, with a stress concentration coefficient of more than 3.0; when the cable anchorage system was located in the connecting sleeve and the threaded splice seam, where corrosion protection was prone to failure, the outer steel wire bore most of the corrosive effects, and the internal cable was less eroded by the corrosive medium.

Numerical and experimental study on corrosion mechanism of the water-oil two-phase flow in the atmospheric tower top system

The atmospheric tower is the main component of the crude oil refining units and is a critical area of concern due to the risk of corrosion failure. Research on the corrosion mechanism and risk protection of atmospheric tower top systems plays a vital role in the safe operation of refineries. In this paper, the water-oil two phase process flow of the atmospheric tower top system was simulated by Aspen software. A corresponding flow corrosion simulation experiment was designed according to the main characteristic parameters of the simulated stream. The experimental results under varying temperature and impact angle conditions were analyzed by using microanalysis technology and CFD simulation methods. The process and mechanism of corrosion failure of tower top system under ammonia salt and dew point corrosion environment are revealed in physicochemical aspects. The results show that the corrosion rate was highest at the dew point temperature, but as the temperature decreases, the corrosion products adsorbed and accumulated on the surface are more difficult to remove from the surface, which slows down the corrosion rate. When the impact angle increased from 0° to 60°, the increment of the surface fluid impact force and turbulence intensity makes the corrosion products easier to be stripped off, which enhances the mass transfer efficiency between the corrosive medium and the surface to accelerate the corrosion rate. Different phase states and flow modes affected the morphology of corrosion pits on the surface. The depth and size of the pits in only water phase corrosion were larger than those in the two-phase flow corrosion, Additionally, as the impact angle increased from 0°, the morphology of pits changes from a relatively flat pattern to a more undulating shape. The research results reveal the characteristics of the main corrosion types occurring in the atmospheric tower top system of the oil refining industry, and provide a reference for corrosion risk protection methods.

Effect of heat treatment on the microstructure and corrosion performance of 2219 Al alloy cold sprayed coatings

This study investigates the influence of different heat treatment conditions on the microstructure and corrosion performance of cold-sprayed coatings on 2219 Al alloy. The results indicate that heat treatment aging effectively improves plastic deformation within the coatings. The direct aging promotes grain refinement, optimization of misorientation angles, which effectively resist the penetration of corrosive media. The coating corrosion initially manifests as pitting corrosion, where interconnected pits lead to particle exposure, initiating intergranular corrosion, and eventually evolving into exfoliation corrosion. The corrosion resistance ranking is as follows: direct aging coatings > solution aging coatings > room temperature coatings > base material.

Formation Mechanism and Prevention of Cu Undercut Defects in the Photoresist Stripping Process of MoNb/Cu Stacked Electrodes

The Cu undercut is a recently discovered new defect generated in the wet stripping process of MoNb/Cu gate stacked electrodes for thin-film transistors (TFTs). The formation mechanism and preventive strategy of this defect were identified and investigated in this paper. The impact of stripper concentration and stripping times on the morphology and the corrosion potential (Ecorr) of Cu and MoNb were studied. It is observed that the undercut is Cu tip-deficient, not the theoretical MoNb indentation, and the undercut becomes severer with the increase in stripping times. The in-depth mechanism analysis revealed that the abnormal Cu undercut was not ascribed to the galvanic corrosion between MoNb and Cu but to the local crevice corrosion caused by the corrosive medium intruding along the MoNb/Cu interface. Based on this newly found knowledge, three possible prevention schemes (MoNiTi (abbreviated as Mo technology development (MTD) layer/Cu), MoNb/Cu/MTD, and MoNb/Cu/MoNb) were proposed. The experimental validation shows that the Cu undercut can only be completely eliminated in the MoNb/Cu/MTD triple-stacked structure with the top MTD layer as a sacrificial anode. This work provides an effective and economical method to avoid the Cu undercut defect. The obtained results can help ensure TFT yield and improve the performance of TFT devices.

Degradation law of bond strength of reinforced concrete with corrosion-induced cracks and machine learning prediction model

During long term operation service, reinforced concrete (RC) structures are subjected to corrosive media such as chloride salts, which results in the degradation of interface bond performance, subsequently reducing the load bearing capacity and service life of the structures. To accurately assess the durability of RC structures in environments such as oceans and salt lakes, this study combines experimental methods with machine learning (ML) techniques to explore the degradation patterns and predictive models of bond performance under chloride salt corrosion. Accordingly, a series of central pull-out tests were conducted based on an electrochemical accelerated-dry-wet cycle corrosion regime to investigate the degradation patterns of bond performance between corroded steel bars and concrete under different corrosion degree and corrosion-induced crack widths. By comparatively analyzing the evolution patterns of cracks and the morphology of the steel bars in reinforced concrete specimens and their failure modes, and integrating the mechanical degradation mechanism with chemical and microscopic corrosion mechanisms, an in-depth analysis of the corrosion-induced degradation patterns at the bond interface was performed. The internal relationships between corrosion degree, corrosion-induced crack width and bond strength were discussed, and the variation patterns of bond strength with corrosion-induced crack width and corrosion degree were explored. Moreover, the bond strength patterns were analyzed from an energy perspective. The results indicate that bond strength and bond energy decrease with an increase in the corrosion-induced crack width of the concrete. Additionally, based on the experimental data from this study, ML predictive models for bond strength were established using corrosion-induced crack width as the control variable. The results show that the ML-based bond strength predictive models fit well with the experimental data, offering higher accuracy and reliability compared to traditional bond strength models. The research findings provide significant theoretical basis and practical guidance for safety assessment, maintenance, reinforcement, and full-life design of corroded RC structures.

Construction of a 3D spider web structure with spherical Ho2O3 wrapped by carbon nanofibers for high-efficiency microwave absorption and corrosion protection

Reasonable composition control and microstructure design are the effective ways to realize multi-functional high-performance absorbing materials. In this work, a three-dimensional (3D) spider web structure was designed by the electrospinning and high temperature carbonization technology, where Ho2O3 spheres were wrapped by carbon nanofibers. Herein, the spherical Ho2O3 were surrounded by layers of carbon nanofibers (spider silk), which were like the preys inside the spider's web. This unique bionic structure working in conjunction with the tuned components enables the as-prepared composites with improved impedance matching and enhanced loss capacity. The superior electromagnetic wave absorption performance was obtained as the minimum reflection loss of −61.37 dB at 2.90 mm and the maximum effective absorption bandwidth of 6.88 GHz (11.12–18 GHz) at 2.64 mm. At a thickness of 3.44 mm, the effective absorption bandwidth is 4.80 GHz (8–12.80 GHz), covering the entire X-band. At the same time, the composite soaked in the corrosive medium for 7 days owns a low corrosion current density (10−4 ∼10−6 A cm−2) and a high polarization resistance (105∼107 Ω), which exhibits the obvious anticorrosion ability. This work designs a specific spider web structure with high-performance microwave absorption and corrosion protection.

Selection of technological basis for intelligent anti-corrosion coating for protection of oil refining equipment

Subject of research: intelligent coating to protect oil refining equipment from corrosion, its protective and operational properties. Purpose of research: to develop the composition of an intelligent coating to protect oil refining equipment from corrosion, to study its basic operational characteristics, to test protective properties in aggressive environments. Methods and objects of research: samples made of 09G2C steel used for the manufacture of technological equipment of oil refineries and petrochemical plants, coated with various protective compositions to determine the main characteristics of the composition of the intelligent coating. To study the operational properties, a technique has been developed using magnetic stirrers that simulate the repeated interaction of a corrosive medium with samples. Main results of research: according to the results of climatic tests and chemical resistance of coatings in a corrosive environment, the most effective composition of the base of an intelligent coating with the best protective characteristics has been established and its necessary adhesive properties have been determined.

Effect of grain size on high-temperature corrosion performance of laser cladding inconel 625 coating

As the calorific value of waste-to-energy incineration continues to rise, the corrosion damage to boilers becomes increasingly severe. The impact of the grain size on the high-temperature corrosion resistance of Inconel 625 coating was investigated. The results indicated that the corrosion performance of the coating in 1:1 NaCl–KCl salts at 700 °C for 120 h was highly dependent on the grain size of the coating. The coating fabricated with a laser power of 1800 W and an overlapping distance of 1.5 mm had an average grain size of 13.7 μm and highest hardness, exhibiting the best corrosion performance, with a corrosion weight loss of 1.4 mg/cm2. Coatings processed under different conditions all formed a three-layered structure, with a NiO outermost layer, a Cr2O3 intermediate layer, and an innermost Cr-depletion zone. Coatings with finer grains formed a continuous and dense protective oxide layer of NiO and Cr2O3 due to the rapid diffusion of alloy elements, effectively preventing the invasion of corrosive media and protecting the substrate from corrosion.