Corrosion Resistance Of Coatings Research Articles

Corrosion resistance analysis of Al2O3-TiO2 composite ceramic coatings on carbon steel pipe surfaces

This study investigates the corrosion resistance of Al2O3-TiO2 composite coatings reinforced with multi-walled carbon nanotubes (MWCNTs) on carbon steel pipe surfaces. Coatings were deposited using atmospheric plasma spraying (APS) and high velocity oxy-fuel (HVOF) techniques. Microstructural analysis revealed that HVOF-sprayed coatings exhibited denser and more homogeneous structures compared to APS-sprayed coatings. Electrochemical tests in 3.5 wt% NaCl solution showed that the HVOF-sprayed Al2O3-13 wt% TiO2-1.5 wt% MWCNT coating demonstrated the lowest corrosion current density of 7.6 × 10−9 A/cm2 and the most positive corrosion potential. Hot corrosion tests in a simulated boiler environment (500°C, 1000 h) revealed that this coating also exhibited minimal weight gain (0.9 mg/cm2) and thickness loss (2 μm). The corrosion rate of the optimal coating was 0.05 mm/year, significantly lower than the bare carbon steel (2.45 mm/year). XRD analysis of corroded samples showed that HVOF-sprayed coatings maintained their original phase composition without detectable substrate corrosion products. The superior corrosion resistance of the HVOF-sprayed Al2O3-13 wt% TiO2-1.5 wt% MWCNT coating is attributed to its optimized composition, dense microstructure, and the reinforcing effect of MWCNTs. These findings provide valuable insights for developing advanced coating solutions to mitigate corrosion-related challenges in the oil and gas industry and other harsh industrial environments.

Influences of Sr(OH)2 on the Structure and Corrosion Resistance of Micro‐Arc Oxidation Coatings Formed on TC4 Titanium Alloy

ABSTRACTIn order to improve the comprehensive properties of TC4 titanium alloy, micro‐arc oxidation (MAO) coating is prepared on the surface of a TC4 substrate in a basic electrolyte with varying concentrations of Sr(OH)2. The surface morphology, phase composition, element distribution, and corrosion resistance of MAO coatings are analyzed by scanning electron microscopy, X‐ray diffraction, an energy‐dispersive spectrometer, the electrochemical test, and the erosion–corrosion test. The results show that the voltage of the MAO process increases and then decreases; the surface morphology and density of the coatings are greatly improved after doping Sr(OH)2. When the concentration of Sr(OH)2 is 0.6 g L−1, the thickness, hardness, and adhesion strength of the coating reach the maximum values of 37.04 μm, 836.2 HV, and 21.8 N, respectively. At this time, the wear resistance and corrosion resistance are the best, and the friction coefficient and the corrosion rate are the lowest: 0.3352 and 1.04 × 10−10 mm a−1, respectively.

Hardness and corrosion resistance of Zn coatings on mild steel obtained by electrodeposition and hot-dip galvanization

The purpose of this work is a comparative study of the characteristics of the layers of Zn on a substrate of mild steel from two different processes (electrodeposition and galvanizing), and to review the progress that has been made in understanding the intermetallics phases’ effect on the corrosion behavior. The obtained Zn-containing film was investigated using diverse instrumental methodologies such as microhardness, X-ray diffraction, and potentiodynamic polarization measurements. This study allows the conclusion that the layers of Zn developed have: a homogeneous structure and good hardness. The corrosion test results showed an improvement in corrosion resistance for electrodeposition coatings compared with galvanizing coatings. XRD results identify that the electrodeposition and the galvanizing coatings have similar phases and the maximum hardness is obtained for the galvanizing process. Intermetallic phases were found to influence the corrosion behavior of mild steel. The results show that the size of Fe–Zn particles gradually decreases with the immersion time.

Fluorine containing diamond-like carbon coatings

Fluorine containing diamond-like carbon (DLC) coatings were obtained by CVD deposition using the destruction of gaseous hydrocarbons by a high-energy ion source with an anode layer. The chemical composition, structure, surface energy, mechano-tribological characteristics of the synthesized thin-film material were studied. It has been shown that the fluorine content in the deposited coatings reaches 31 at.%. It has been established that the presence of fluorine in the DLC coating promotes the formation of nanodispersed graphite-like structures. Fluorine containing coatings with a high content of sp2 hybridized carbon atoms and graphite fragments show a decrease in hardness. Such coatings have a very low coefficient of friction at the level of 0.03–0.07 due to the low surface energy, which can be reduced by 1.5 times compared to pure DLC. It has been established that different fluorine contents in thin-film diamond-like carbon material have different effects on the interaction of the DLC coating with polar/non-polar dielectrics. The research results can be used for the technology of producing solid lubricants in friction units of machines and mechanisms, and are also of interest for medicine, the food industry, the production of plastics, and chemical fibers as chemically inert and corrosion-resistant coatings.

Enhanced corrosion resistance of NbTaMoW medium entropy alloy coatings in simulated PEMFC environments: Experimental and computational insights

An anti-corrosive and conductive NbTaMoW medium entropy alloy (MEA) coating was deposited on 304 stainless steel using a dual-cathode glow discharge technology. This MEA coating exhibits a single body-centered cubic phase with about 10 nm grains, and forms a passivation film with significantly enhanced corrosion resistance at any given HF concentration. The lower adsorption energy of Nb atoms for oxygen atoms leads to the enrichment of Nb oxides in the passivation film, which is beneficial for hindering the rapid diffusion of F− ions. These findings underscore the potential of NbTaMoW MEA coatings to improve the durability and efficiency of PEMFCs.

PVD Coatings for Lightweight Bipolar Plates

Bipolar plates are one of the main components of proton exchange membrane fuel cells (PEMFCs). Their functions include distributing reactants, supporting the cell, and conducting heat and electricity. They account for a significant proportion of the fuel cell stack’s weight and volume. The main materials currently used for bipolar plates are graphite and stainless steel. Aluminium has a much lower density than steel and is easier to form than both steel and graphite. Its use, therefore, would allow fuel cells with higher power densities but is hindered due to it being prone to corrosion. This work focused on the development of corrosion-resistant and conductive coatings to address this issue. Carbon coatings with Ti and Cr adhesion layers were deposited on aluminium substrates using closed-field unbalanced magnetron sputtering. These coatings were tested for corrosion properties and performance on the cathode side of a single-cell fuel cell. Coated aluminium samples were also tested for their ability to maintain their corrosion protection after being formed. Coating with a Cr adhesion layer outperformed that with a Ti adhesion layer in both forming and fuel cell tests, demonstrating much lower performance degradation after accelerated stress testing.

Enhancing Resistance to Corrosion and Fouling Using Epoxy Coatings with Superhydrophobic Cells

AbstractAs maritime transport becomes increasingly important, metal corrosion results in significant economic losses. Superhydrophobic materials have significant potential for corrosion prevention. However, poor compatibility between superhydrophobic materials and resin reduces the long‐term corrosion resistance. Interfacial strengthening cells (IS‐Cells) are designed to maintain superhydrophobicity and retain active hydroxyl groups participating in resin‐curing. IS‐Cells also contribute to achieving the maze effect. A novel anti‐corrosion IS coating is fabricated by compatible IS‐Cells and epoxy. IS coatings feature smooth surfaces and vertical compactness, protecting against liquid and gaseous corrosive medium. Strong diffusion resistance and extended diffusion distance ensure long‐term corrosion resistance of IS coatings. Approximately 85 µm of IS coatings remain corrosion‐free after 112 days of immersion in the NaCl solution. The low‐frequency impedance, self‐corrosion potential, and self‐corrosion current density are 1.68 × 109 Ω cm2, −0.0708 V, and 5.38 × 10−11 A cm−2, respectively. IS coatings can also withstand 2400 h of neutral salt spray testing without corrosion in the artificial scratches. Due to the electrostatic repulsion between the hydrophobic C–F chains onto IS‐Cells and protein molecules, IS coatings maintain anti‐fouling properties after dry‐wet immersion tests in the natural marine environment for 90 days. IS coatings show great potential for marine anti‐corrosion applications.

Significantly enhanced corrosion resistance for Fe-based amorphous coatings via sealing treatment: Based on hybridisation and superhydrophobicity strategy

Based on the synergistic effect of hybridisation-superhydrophobicity, a simple and facile spraying method was used to achieve efficient sealing of Fe-based amorphous metallic coatings. In this paper, we employed rare-earth neodymium salts as inorganic sealant raw materials and loaded low surface energy fluorosilanes into epoxy resins to act as organic sealant raw materials. The surface structure and chemical composition of the sealing coatings were systematically characterised. The sealing mechanism as well as the anti-corrosion mechanism of the coating were investigated intensively. The results indicate that the superior corrosion resistance and self-cleaning ability of the sealed coating stems from the inorganic–organic-complex trinity effect: the corrosion inhibition effect of Nd oxide deposited during the inorganic sealing process, the shielding effect of the resin in the organic sealing, and the cross-linking and superhydrophobicity behaviour (liquid repellency effect) of the FDTES-Nd3+-Fe2+ complexes formed on the surface of the coating. This work provides valuable guidelines and insights for the design of subsequent corrosion-resistant and sealing coating.

Enhanced hydrophobic properties, wear and corrosion resistance of plasma electrolyte oxidation coatings on AZ31B magnesium alloys with addition of TiO2 nanoparticles

Enhanced hydrophobic properties, wear and corrosion resistance of plasma electrolyte oxidation coatings on AZ31B magnesium alloys with addition of TiO2 nanoparticles

Investigating the effectiveness of graphene oxide and hydroxylated hexagonal boron nitride to improve the coating corrosion resistance from electrochemistry and simulation perspectives

The performance of GO and hydroxylated BN in improving the corrosion resistance of a water-borne epoxy coating was comparatively investigated to evaluate the relative excellence of two nanofillers. Electrochemical tests indicated that GO outperformed hydroxylated BN. The corrosion current density was further decreased to 3.48 × 10−6 A/cm2 and polarization resistance was increased to 8.67 × 104 Ω·cm2. The electrochemical reactivity was also most significantly decreased with incorporating GO. Without changing the coating structure, the superior performance of GO was attributed to its exceptional ability to capture water molecules as revealed by simulation results. The mass transfer process of water molecules within coatings was inhibited and the redox reactions during corrosion process were thereby effectively controlled.

A Comparative Study on the Corrosion Resistance and Long-Term Stability of Hierarchical Superhydrophobic Nickel Coatings Obtained by One-Step and Two-Step Electrodeposition Processes

A Comparative Study on the Corrosion Resistance and Long-Term Stability of Hierarchical Superhydrophobic Nickel Coatings Obtained by One-Step and Two-Step Electrodeposition Processes

Microstructure, Hardness and High-Temperature Corrosion Behaviors in Sulfur-Containing Environment of Laser Cladding Y2O3/IN625 Composite Coating

Water-cooled wall tubes are susceptible to high-temperature corrosion during service. Applying high-performance coatings via laser cladding on the tube surfaces can significantly enhance corrosion resistance and extend the service life of the tubes, providing substantial economic advantages. This paper prepared Y2O3/IN625 composite coating by means of high-speed laser cladding. Furthermore, the effects of Y2O3 addition on the microstructure evolution, hardness, as well as the high-temperature corrosion behaviors have been systematically investigated. The results show that Y2O3 addition can effectively refine the microstructure of the Inconel 625 coating, but the phase composition has little change. The coating’s hardness can also be improved by about 7.7%, reaching about 300 HV. Compared to Inconel 625 coating, the Y2O3-added composited coating shows superior high-temperature corrosion resistance, with the corrosion mass gain decreased by about 36.6%. The denser and tightly bonded Cr-rich oxides layer can be formed adjacent to the coating surface, which plays a predominant role in improving the coating corrosion resistance.

Chitosan and Its Derivatives as a Barrier Anti-Corrosive Coating of 304 Stainless Steel against Corrosion in 3.5% Sodium Chloride Solution

This study investigates the corrosion resistance of chitosan and its crosslinked form coatings applied on stainless steel as substrate using various analytical techniques. Fourier transform infrared spectroscopy (FTIR-ATR), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) were employed for surface characterization. Electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) techniques were used to analyze the electrochemical behavior. Four coatings were evaluated along with naked stainless steel (ss): chitosan (Chi), chitosan crosslinked with ammonium paratungstate (Chi/PTA), chitosan crosslinked with polyethylene glycol (Chi/PEG), and chitosan crosslinked with polyvinylpyrrolidone (Chi/PVP). Electrochemical measurement parameters analysis assessed the coating corrosion resistance, such as impedance modulus (|Z|) and corrosion potential (Ecorr). Results indicate varying degrees of corrosion resistance among the coatings. Chi/PTA exhibited notable characteristics in the electrochemical tests, showing promising polarization resistance (Rp) and impedance behavior trends. Conversely, Chi/PEG showed differing electrochemical responses, suggesting higher susceptibility to corrosion under the study conditions. These findings contribute to understanding the electrochemical performance of chitosan-based coatings on stainless steel, highlighting their potential in corrosion protection applications.

STRUCTURE FORMATION OF Ni−P ALLOY ELECTROCOATINGS WITH INCREASED CORROSION RESISTANCE

Purpose of research. The main factors that reduce the protective properties of electrocrystallized coatings are the formation of volumetric defects − pores, as well as the occurrence of microgalvanic couples at grain boundaries, that is, on surface defects of the crystalline structure. Creating a non-porous structure in electrocoatings, eliminating the formation of surface defects in metal/alloy layers, as well as the possibility of replacing chromium coatings, which are obtained from toxic electrolytes, are urgent tasks. Materials and methodology. In the work, it was proposed to use electrocoatings with Ni−P alloy as protective layers on products that increase corrosion resistance. An X-ray determination of the phase composition of Ni−P electrochemical deposits was carried out. The surface morphology and corrosion resistance of coatings were studied. Results. Samples of electrochemical coatings of pure nickel and nickel-phosphorus alloy were studied. It has been established that during the formation of nickel coatings with the addition of phosphorus ions, the surface morphology has practically no pores, amorphization of deposits occurs, due to which the protective properties, namely, corrosion resistance, are improved. Scientific novelty. Factors have been identified that influence the increase in corrosion resistance of coatings − the absence of a porous structure and the formation of an amorphous state. Conclusions. The influence on the structure and properties of electrochemical coatings of a nickel-phosphorus alloy has been studied. It has been established that the addition of phosphorus ions to the nickel plating electrolyte leads to the formation of an amorphous structure in the coatings, and layers of the Ni−P alloy appear practically without the presence of pores. It has been established that the effect of increasing the corrosion resistance of the electrochemical coating with a nickel-phosphorus alloy (by 30 %) is due to the formation of an amorphous structure of the solidifying metal liquid while preventing the crystallization process during electrochemical deposition.

Superhydrophobic Corrosion-Resistant Coating of AZ91D Magnesium Alloy: Preparation and Performance

This research presents the development of a surface treatment for AZ91D magnesium alloy that exhibits both superhydrophobic and anticorrosive properties. Initially, a zinc-based phosphate film was deposited on the magnesium alloy surface. Subsequently, a composite coating with superhydrophobic properties was produced by surface modification using a fluorosilane-ethanol solution. The composite coating’s microstructure, chemical composition, wettability, self-cleaning, and anti-corrosion properties were evaluated using scanning electron microscopy, a contact angle measurement instrument, and an electrochemical workstation. The results demonstrated that the main components of the composite coating were P, O, Zn, F, and C. The static contact angle reached 158°, providing superior self-cleaning and acid and alkali corrosion resistance. Additionally, the charge transfer resistance and coating resistance of the composite coating were significantly higher than those of the magnesium alloy substrate, effectively preventing corrosion and preserving the surface from fouling.

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

The introduction of poly(tannic acid) (PTA) and cerium ion [Ce(III)] on the surface of α-zirconium phosphate (α-ZrP) endowed the α-ZrP@PTA-Ce(III)/waterborne epoxy composite coating with enhanced corrosion protection and wear resistance performances. The successful preparation of α-ZrP@PTA-Ce(III) was confirmed through X-ray diffraction, X-ray photoelectron spectroscopy, and Fourier transform infrared spectra. PTA improved the compatibility between α-ZrP@PTA-Ce(III) and the waterborne epoxy resin due to the presence of organic groups from tannic acid. The wear resistance test indicated that the incorporation of α-ZrP@PTA-Ce(III) effectively reduced the coefficient of friction and the wear rate. Electrochemical impedance spectroscopy was used to analyze the corrosion protection performance of unbroken coatings and the self-healing ability of scratched coatings. The incorporation of α-ZrP@PTA-Ce(III) improved the protection performace distinctly. In addition, α-ZrP@PTA-Ce(III) endowed the composite coating with dual corrosion inhibition effects, originating from the PTA film, to prevent the penetration of corrosive media and a dense film that came from the Ce(III) cation. The waterborne epoxy system with enhanced corrosion and wear resistance in this paper broadens the application of α-ZrP.

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.

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-4 A/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.

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.