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Corrosion performance of bi-layer Ni/Cr2C3–NiCr HVAF thermal spray coating
University West, Department of Engineering Science, Research Environment Production Technology West. Amirkabir University of Tehran, Tarbiat Modares University of Tehran. (Thermal Spray)ORCID iD: 0000-0002-7663-9631
University West, Department of Engineering Science, Division of Manufacturing Processes.ORCID iD: 0000-0002-9578-4076
University West, Department of Engineering Science, Research Enviroment Production Technology West. (PTW)ORCID iD: 0000-0001-7787-5444
University West, Department of Engineering Science, Division of Mechanical Engineering. (PTW)ORCID iD: 0000-0003-1181-0415
2016 (English)In: Applied Surface Science, ISSN 0169-4332, E-ISSN 1873-5584, Vol. 369, 470-481 p.Article, review/survey (Refereed) Published
Abstract [en]

The corrosion behavior of three HVAF thermal spray coating systems (A: single-layer Ni, B: single-layer Cr2C3–NiCr coatings, and C: bi-layer Ni/Cr2C3–NiCr coating) was comparatively studied using immersion,salt spray, and electrochemical tests. Polarization and EIS results showed that the corrosion behavior of Cr2C3–NiCr coatings in 3.5 wt.% NaCl solution was significantly improved by adding the intermediate layer of Ni. It was illustrated that the polarization resistance of the bi-layer Ni/Cr2C3–NiCr and singlelayerCr2C3–NiCr coatings were around 194 and 38 k cm2, respectively. Microstructure analysis revealed that the bond coating successfully prevented the corrosion propagation toward the coating.

Place, publisher, year, edition, pages
Amsterdam: Elsevier, 2016. Vol. 369, 470-481 p.
Keyword [en]
Thermal spray, HVAF Corrosion, EIS, Polarization, Immersion test
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-9293DOI: 10.1016/j.apsusc.2016.02.002ISI: 000374203000060Scopus ID: 2-s2.0-84958787256OAI: oai:DiVA.org:hv-9293DiVA: diva2:917622
Available from: 2016-04-07 Created: 2016-04-07 Last updated: 2016-12-16Bibliographically approved
In thesis
1. Corrosion Behavior of HVAF-Sprayed Bi-Layer Coatings
Open this publication in new window or tab >>Corrosion Behavior of HVAF-Sprayed Bi-Layer Coatings
2016 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

In a variety of engineering applications, components are subjected to corrosive environment. Protective coatings are essential to improve the functional performances and/or extend the lifetime of the components. Thermal sprayingas a cost-effective coating deposition technique offers high flexibility in coatings' chemistry/morphology/microstructure design. However, the inherent pores formed during spraying limit the use of coatings for corrosion protection. The recently developed supersonic spray method, High-Velocity-Air-Fuel (HVAF), brings significant advantages in terms of cost and coating properties. Although severely reduced, the pores are not completely eliminated even with the HVAF process. In view of the above gap to have a high quality coating, bi-layer coatings have been developed to improve the corrosion resistance of the coatings. In a bi-layer coating, an intermediate layer is deposited on the substrate before spraying the coating. The electrochemical behavior of each layer is important to ensure a good corrosion protection. The corrosion behavior of the layers strongly depends on coating composition and microstructure, which are affected by feedstock material and spraying process. Therefore, the objective of the researchis to explore the relationships between feedstock material, spraying process, microstructure and corrosion behavior of bi-layer coatings. A specific motivationis to understand the corrosion mechanisms of the intermediate layer which forms the basis for developing superior protective coatings. Cr3C2-NiCr top layer and intermediate layers (Fe-, Co- and Ni-based) were sprayed by different thermal spraying processes. Microstructure analysis, as well as various corrosion tests, e.g., electrochemical, salt spray and immersion tests were performed. The results showed a direct link between the corrosion potential (Ecorr) of the intermediate layer and the corrosion mechanisms. It was found that the higher corrosion resistance of Ni-based coatings than Fe- and Co-based coatings was due to higher Ecorr of the coating in the galvanic couple with top layers. Inter-lamellar boundaries and interconnected pores reduced the corrosion resistance of intermediate layers, however a sufficient reservoir of protective scale-forming elements (such as Cr or Al) improved the corrosion behavior.

Place, publisher, year, edition, pages
Trollhättan: University West, 2016. 59 p.
Series
Licentiate Thesis: University West, 10
Keyword
Thermal spray coating, HVAF, Corrosion protection, Galvanic corrosion, Composition, Microstructure, EIS, Polarization, OCP
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-9929 (URN)978-91-87531-33-0 (ISBN)978-91-87531-32-3 (ISBN)
Presentation
2016-09-30, C118, University West, Trollhättan, 10:15 (English)
Supervisors
Available from: 2016-09-30 Created: 2016-09-22 Last updated: 2016-09-30Bibliographically approved

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