Effects of thickness coating on the electrochemical behaviour of thermal spray Cr3C2-NiCr coatings

Thermally sprayed HVOF coatings are increasingly being used in industrial applications where high wear and corrosion resistance are needed [1,2]. In this paper, electrochemical ac and de experiments were used in order to obtain the corrosion resistance of coated steel with different numbers of Cr3C2-NiCr layers. This work has been performed in order to determine the role of coating thickness in the corrosion behaviour of a steel protected with cermet thermally sprayed coatings. It is known that a thicker layer protects better against corrosion when a metallic coating is evaluated. But cermet coatings, such as Cr3C2-NiCr, contain higher levels of porosity and residual stresses than metallic coatings, which really could influence the corrosion resistance of the deposited layer. Electrochemical measurements, such as Open-Circuit Potential (E-Osubset of), Polarisation Resistance (RP) and Cyclic Voltammetry (CV), were performed in an aerated 3.4 NaCI media (%wt.). Electrochemical Impedance Measurements (EIS) were also done in order to obtain a mechanism that explains the corrosion process. Structural Characterisation was carried out by means of Optical and Scanning Electron Microscopes (OM, SEM) with an Energy Dispersive Spectrometry analyser (EDS). Results show that the corrosion resistance of the complete system is mainly influenced by the substrate behaviour. The application of a higher number of deposited layers did not substantially increase their anticorrosive properties. Stress generation during the spraying deposition process plays an important role in the behaviour of the coated steel against corrosion phenomena. (C) 2002 Elsevier B.V. B.V All rights reserved.

Cr3C2-NiCr and WC-Ni thermal spray coatings as alternatives to hard chromium for erosion-corrosion resistance

Cr3C2-NiCr and WC-Ni coatings are widely used for wear applications at high and room temperature, respectively. Due to the high corrosion resistance of NiCr binder, Cr3C2-NiCr coatings are also used in corrosive environments. The application of WC-Ni coatings in corrosive media is 14 not recommended due to the poor corrosion resistance of the (pure Ni) metallic matrix. It is well known that the addition of Cr to the metallic binder improves the corrosion properties. Erosion-corrosion performance of thermal spray coatings is widely influenced by ceramic phase composition, the size of ceramic particles and also the composition of the metallic binder. In the present work, two types of HVOF thermal spray coatings (Cr3C2-NiCr and WC-Ni) obtained with different spray conditions were studied and compared with conventional micro-cracked hard chromium coatings. Both as-sprayed and polished samples were tested under two erosion-corrosion conditions with different erosivity. Tungsten carbide coatings showed better performance under the most erosive condition, while chromium carbide coatings were superior under less erosive conditions. Some of the tungsten carbide coatings and hard chromium showed similar erosion-corrosion behaviour under more and less erosive conditions. The erosion-corrosion and electrochemical results showed that surface polishing improved the erosion-corrosion properties of the thermally sprayed coatings. The corrosion behaviour of the different coatings has been compared using Electrochemical Impedance Spectroscopy (EIS) and polarization curves. Total material loss due to erosion-corrosion was determined by weight loss measurements. An estimation of the corrosion contribution to the total weight loss was also given. (c) 2007 Elsevier B.V. All rights reserved.

Influence of thermal treatments in the corrosion behaviour of HVOF Cr 3C2-NiCr coatings

Thermal spray coatings as Cr3C2-NiCr obtained by high velocity oxy-fuel spraying (HVOF) are mainly applied due to their behaviour against aggressive erosive-abrasive and corrosive atmospheres and their thermal stability at high temperatures [1]. In order to increase the corrosion protection that it offers to the substrate trying to close the interconnected pores, it is possible to apply a thermal treatment with the gun during the spraying of the coating. This treatment could be applied in different ways. One of these ways consists of spraying only a few layers of coating followed by thermal treatment and finally the spray of the rest of layers. This thermal treatment on spraying is studied related to the corrosion properties of the system. The study comprises the electrochemical characterisation of the system by open circuit potential (OC), polarisation resistance (Rp), cyclic voltammetry (CV) and impedance spectroscopy measurements (EIS). Optical and scanning electron microscopy characterisation (OM and SEM) of the top and cross-section of the system has been used in order to justify the electrochemical results.

Influence of spraying parameters on the electrochemical behaviour of HVOF thermally sprayed stainless steel coatings in 3.4% NaCl

Stainless steel coatings obtained by High Velocity Oxygen Fuel (HVOF) were characterized using optical (OM) and scanning electron microscopy (SEM), electron probe micro-analysis, X-ray diffraction (XRD), open-circuit potential (E-OC) measurements, electrochemical impedance spectroscopy (EIS) and polarisation tests. Differences among coated steels were mainly related with the gun-substrate distance parameter (310 nm for samples A and B and 260 min for C and D). The open-circuit potential values measured for all the samples after 18 h of immersion in aerated and unstirred 3.4% NaCl solution were: - 0.334, - 0.360, - 0.379 and - 0.412 V vs. Ag/AgCl,KClsat. for samples A to D, respectively. For EIS measurements, Nyquist plots showed higher capacitive semi-circle for samples sprayed at longer distance, indicating higher corrosion resistance in NaCl solution. (c) 2005 Elsevier B.V. All rights reserved.

The influence of gun transverse speed on electrochemical behaviour of thermally sprayed Cr3C2-NiCr coatings in 0.5 M H2SO4 solution

In the present study, different types of 75% Cr3C2-25% NiCr coatings were applied on a steel substrate by means of high velocity oxygen fuel spraying (HVOF), and studied using ac and dc electrochemical measurements in an aerated and unstirred 0.5 M H2SO4 solution. Structural characterization was determined before and after electrochemical tests. Differences between all sprayed systems are related to the gun transverse speed and number of deposited layers, which strongly affected the electrochemical characteristics of the coated steels. The coating obtained with a higher torch speed showed better resistance against corrosion. The electrochemical impedance results were analyzed using an equivalent circuit where porosity of the coatings and substrate oxidation were considered. (C) 2003 Elsevier Ltd. All rights reserved.

Electrochemical behavior of thermally sprayed stainless steel coatings in 3.4% NaCl solution

Four types of stainless steel coatings prepared by a high velocity oxy-fuel spraying system (HVOF) were studied. Differences among coated steels were related to the spraying parameters, which influenced the behavior of the samples against the corrosion. The electrochemical behavior of the stainless steel coatings was strongly influenced by porosity, the presence of micro- and macro-cracks, and also of un-melted particles. Once the electrolyte reached the steel substrate via these defects, the galvanic pair formed between the coating and substrate-accelerated corrosion, leading to the depletion of the coating. (C) 2004 Elsevier Ltd. All rights reserved.

Electrochemical behaviour of thermally sprayed Cr3C2-NiCr coatings in 0.5 M H2SO4 media

The electrochemical behaviour of coated Cr3C2-NiCr steel in aerated 0.5 M H2SO4 solution was studied by means of electrochemical a.c. and d.c. measurements. A complete structural characterization of the coated steel before and after electrochemical tests was also carried out to access the corrosion mechanism of coated steel, electrolyte penetration through the coating, and to confirm the results obtained using electrochemical techniques. Two types of Cr3C2-NiCr coatings produced by a high velocity oxy-fuel spraying system (HVOF) were studied. Differences between coated steels are related to the spraying parameters reflecting their behaviour against corrosion phenomena. The electrochemical behaviour of the coated steel was strongly influenced by porosity and the presence of microcracks in the coating. Once the electrolyte reaches the steel substrate, it corrodes in a galvanic manner resulting in coating detachment from the steel.

WC-CoCr coatings sprayed by high velocity oxygen-fuel (HVOF) flame on AA7050 aluminum alloy: electrochemical behavior in 3.5% NaCl solution

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Influence of HVOF parameters on the corrosion and wear resistance of WC-Co coatings sprayed on AA7050 T7

Thermal spray WC-based coatings are widely used in the aircraft industry mainly for their resistance to wear, reworking and rebuilding operations and repair of worn components on landing gear, hydraulic cylinders, actuators, propeller hub assemblies, gas turbine engines, and so on. The aircraft industry is also trying to use thermal spray technology to replace electroplating coatings such as hard chromium. In the present work, WC-Co coatings were built up on an AA 7050 aluminum alloy using high velocity oxygen fuel (HVOF) technology and a liquid nitrogen cooling prototype system. The influence of the spray parameters (standard conditions, W19S, increasing the oxygen flux, W19H, and also increasing the carrier gas flux, W19F) on corrosion, friction, and abrasive wear resistance were also studied. The coatings were characterized using optical (OM) and scanning electron (SEM) microscopy, and X-ray diffraction (XRD). The friction and abrasive wear resistance of the coatings were studied using Rubber Wheel and Ball on Disk tests. The electrochemical studies were conducted using open-circuit potential (E(oc)) measurements and electrochemical impedance spectroscopy (EIS). Differences among coated samples were mainly related to the variation of the thermal spray parameters used during the spray process. No significant differences were observed in the wear resistance for the coatings studied, and all of them showed a wear rate around 10 times lower than that of the aluminum alloy. The results of mass loss and wear rate were interpreted considering different mechanisms. Comparing the different spray parameters, the oxygen flux (higher flame temperature) produced the sample which showed the highest corrosion resistance in aerated and unstirred 3.5% NaCl solution. Aluminum ions were detected on the surface almost immediately after the immersion of samples W19S and W19F in chloride solution, showing that the electrolyte reached the substrate and galvanic corrosion probably occurred. For sample W19H, aluminum ions were not detected even after 120 min of immersion in NaCl solution. (C) 2008 Elsevier B.V. All rights reserved.

Corrosion and Wear Studies of Cr3C2NiCr-HVOF Coatings Sprayed on AA7050 T7 Under Cooling

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Corrosion behaviour of thermal sprayed nitinol coatings

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

An investigation on sliding wear behavior of PVD coatings

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Fatigue strength of HVOF sprayed Cr(3)C(2)-25NiCr and WC-10Ni on AISI 4340 steel

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Comparative study of Cr3C2-NiCr coatings obtained by HVOF and hard chromium coatings

In the present work the corrosion resistance of micro-cracked hard chromium and Cr3C2-NiCr (HVOF) coatings applied on a steel substrate have been compared using open-circuit potential (E-OC) measurements, electrochemical impedance spectroscopy (EIS) and polarization curves. The coatings surfaces and cross-section were characterized before and after corrosion tests using optical microscopy (OM) and scanning electron microscopy (SEM). After 18 h of immersion, the open-circuit potential values were around -0.50 and -0.25V/(Ag vertical bar AgCl vertical bar KClsat) for hard chromium and Cr3C2- NiCr, respectively. The surface analysis done after 12 h of immersion showed iron on the hard chromium surface inside/near surface cracks, while iron was not detected on the Cr3C2-NiCr surface even after 18 h. For longer immersion time hard chromium was more degraded than thermal sprayed coating. For hard chromium coating a total resistance values between 50 and 80 k Omega cm(2) were measured and two well-defined time constants were observed, without significant change with the immersion time. For Cr3C2-NiCr coating the total impedance diminished from around 750 to 25 k Omega cm(2) as the immersion time increased from 17 up to 132 h and two overlapped time constants were also observed. Polarization curves recorded after 18 h of immersion showed a lower current and higher corrosion potential for Cr3C2-NiCr coating than other samples studied. (c) 2005 Elsevier Ltd. All rights reserved.

Development of amorphous carbon protective coatings on poly(vinyl)chloride

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)