1 College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, Hunan, China 2 State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, Hunan, China 3 Light Alloy Research Institute, Central South University, Changsha 410083, Hunan, China 4 College of Mechanical Engineering, University of South China, Hengyang 421001, Hunan, China
Thermal-sprayed coating of optimally mixed ceramic powders on stainless steel with enhanced corrosion resistance
1 College of Mechanical and Electrical Engineering, Central South University, Changsha 410083, Hunan, China 2 State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, Hunan, China 3 Light Alloy Research Institute, Central South University, Changsha 410083, Hunan, China 4 College of Mechanical Engineering, University of South China, Hengyang 421001, Hunan, China
ժҪ Three different groups of ceramic powders for the thermal-sprayed coating were fi rstly prepared using sintering and ball milling. Then, these powders were separately deposited on three stainless steel substrates, followed by individual corrosion resistance examination. Microstructural characterization showed that the levels of micro-void and micro-crack at the bonding interface (between coating and substrate) depended on the proportions of different ceramic particles. Meanwhile, a signifi cantly enhanced corrosion resistance was reproducibly observed in one group of as-coated samples that have the optimal combination of given ceramic powders. Furthermore, the mechanism of corresponding enhanced corrosion resistance was discussed. It was found that the optimal ceramic powders for the present thermal-sprayed coating should contain 30.2 wt% SiO2, 54 wt% Cr2O3, 6.8 wt% Al2O3, 4.8 wt% CaO and 1.8 wt% TiO 2. The corrosion velocities of such samples .2 in the 3.5 vol.% HCl, 15 wt% NaOH and 5 wt% NaCl solutions were 3.74, 2.98 and 0.50 g h .1 m for 168, 336 and 336 h, respectively.
Abstract��Three different groups of ceramic powders for the thermal-sprayed coating were fi rstly prepared using sintering and ball milling. Then, these powders were separately deposited on three stainless steel substrates, followed by individual corrosion resistance examination. Microstructural characterization showed that the levels of micro-void and micro-crack at the bonding interface (between coating and substrate) depended on the proportions of different ceramic particles. Meanwhile, a signifi cantly enhanced corrosion resistance was reproducibly observed in one group of as-coated samples that have the optimal combination of given ceramic powders. Furthermore, the mechanism of corresponding enhanced corrosion resistance was discussed. It was found that the optimal ceramic powders for the present thermal-sprayed coating should contain 30.2 wt% SiO2, 54 wt% Cr2O3, 6.8 wt% Al2O3, 4.8 wt% CaO and 1.8 wt% TiO 2. The corrosion velocities of such samples .2 in the 3.5 vol.% HCl, 15 wt% NaOH and 5 wt% NaCl solutions were 3.74, 2.98 and 0.50 g h .1 m for 168, 336 and 336 h, respectively.
L. Benramoul, A.A. El-Hadj, An elastic-perfectly plastic model for simulating an aluminum particle behavior during plasma thermal spraying using the finite element method, Appl. Surf. Sci. 258 (2011) 962-971.
[2]
W.C. Gu, G.H. Lv, H. Chen, G.L. Chen, W.R. Feng, G.L. Zhang, S.Z Yang, Preparation of ceramic coatings on inner surface of steel tubes using a combined technique of hot-dipping and plasma electrolytic oxidation, J. Alloys Comp. 430 (2007) 308-312.
[3]
E. Garcia, J. Mesquita-Guimar?es, P. Miranzo, M.I. Osendi, Porous mullite and mullite�CZrO2 granules for thermal spraying applications, Surf. Coatings Tech. 205 (2011) 4304-4311.
[4]
C. Bartuli, L. Lusvarghi, T. Manfredini, T. Valente, Thermal spraying to coat traditional ceramic substrates: Case studies, J. Eur. Ceramic Soc. 27 (2007) 1615-1622.
[5]
R.S.C. Paredes, S.C. Amico, A.S.C.M. D��Oliveira, The effect of roughness and pre-heating of the substrate on the morphology of aluminium coatings deposited by thermal spraying, Surf. Coatings Tech. 200 (2006) 3049-3055.
[6]
J.H. Choi, C. Lee, D.B. Lee, Oxidation behavior of bulk amorphous Ni57Ti18Zr20Si3Sn2 coatings between 473 and 973 K in air, J. Alloys Comp. 449 (2008) 384-388.
[7]
E. Garcia, C. Cano, T.W. Coyle, M.I. Osendi, P. Miranzo, Thermally Sprayed CaZrO Coatings, J. Thermal Spray Tech. 17 (2008) 865-871.
[8]
I.A. Gorlach, A new method for thermal spraying of Zn�CAl coatings, Thin Solid Films 517 (2009) 5270-5273.
[9]
Y. Wu, S. Hong, J. Zhang, Z. He, W. Guo, Microstructure and cavitation erosion behavior of WC-Co-Cr coating on 1Cr18Ni9Ti stainless steel by HVOF thermal spraying, Inter. J. Refractory Metals Hard Mater. 32 (2012) 21-26.
[10]
S. Kamnis, S. Gu, N. Zeoli, Mathematical modelling of Inconel 718 particles in HVOF thermal spraying, Surf. Coatings Tech. 202 (2008) 2715-2724.
[11]
H. Tabbara, S. Gu, Computational simulation of liquid-fuelled HVOF thermal spraying, Surf. Coatings Tech. 204 (2009) 676-684.
[12]
J.C. Tan, L. Looney, M.S.J. Hashmi, Component repair using HVOF thermal spraying, J. Mater. Proc. Tech. 92-93 (1999) 203-208.
[13]
P. Ctibor, I. P��?, J. Kotlan, Z. Pala, I. Khalakhan, V. ?tengl, P. Homola, Microstructure and Properties of Plasma-Sprayed Mixture of CrO and TiO, J. Thermal Spray Tech. 22 (2013) 1163-1169.
S. Dong, B. Song, B. Hansz, H. Liao, C. Coddet, Microstructure and properties of Cr 2 O 3 coating deposited by plasma spraying and dry-ice blasting, Surf. Coatings Tech. 225 (2013) 58-65.
[16]
J. Pina, A. Dias, J.L. Lebrun, Mechanical stiffness of thermally sprayed coatings and elastic constants for stress evaluation by X-ray diffraction, Mater. Sci. Eng. A 267 (1999) 130-144.
[17]
Q. Wang, D. Qiu, Y.M. Xiong, N. Birbili, M.X. Zhang, High resolution microstructure characterization of the interface between cold sprayed Al coating and Mg alloy substrate, Appl. Surf. Sci. 289 (2014) 366-369
[18]
C. Lee, J. Kim, Microstructure of Kinetic Spray Coatings: A Review, J. Therm. Spray Tech. 24 (2015) 592-610.
[19]
P.C. King, S.H. Zahiri, M. Jahedi, Focused ion beam micro-dissection of cold-sprayed particles, Acta Mater. 56 (2008) 5617-5626.
[20]
V.K. Champangne, D. Helfritch, P. Leyman, S. Grendahl, B. Klotz, Interface material mixing formed by the deposition of copper on aluminum by means of the cold spray process, J. Therm. Spray Tech. 14 (2005) 330-334.
[21]
G.M. Song, S.B. Li, C.X. Zhao, W.G. Sloof, S. van der Zwaag, Y.T. Pei, J.T.M. De Hosson, Ultra-high temperature ablation behavior of Ti2AlC ceramics under an oxyacetylene flame, J. Euro. Ceramic Soc. 31 (2011) 855-862.
[22]
Y.F Tan, P. Martin, C. Lescalier, O. Bomont, R. Bigot, J. Arzur, Study on the Ground Surface Quality of Cr2O3 Coatings, J. Mater. Pro. Tech. 129 (2002) 441-445.
[23]
G. Ji, J.P. Morniroli, T. Grosdidier, Nanostructures in thermal spray coatings, Scripta Mater. 48 (2003) 1599-1604.
[24]
J. Matejicek, S. Sampath, Intrinsic residual stresses in single splats produced by thermal spray processes, Acta Mater. 49 (2001) 1993-1999.
[25]
P.K. Huang, J.W. Yeh, T.T. Shun, S.K. Chen, Multi-principal-element alloys with improved oxidation and wear resistance for thermal spray coating, Adv. Eng. Mater. 6 (2004) 74-78.