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Acta Metall Sin  2018, Vol. 54 Issue (8): 1193-1203    DOI: 10.11900/0412.1961.2017.00491
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Microstructure and Corrosion Properties of Aluminum Base Amorphous and Nanocrystalline Composite Coating
Xiubing LIANG1,2(), Jianwen FAN1, Zhibin ZHANG1, Yongxiong CHEN1,2
1 National Engineering Research Center for Mechanical Product Remanufacturing, Academy of Armored Army Forces, Beijing 100072, China
2 Innovation Research Institute of National Defense Science and Technology, Academy of Military Sciences, Beijing 100071, China
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It is easy to corrode the steel structural materials. In view of this problem, the Al-Ni-Zr amorphous and nanocrystalline composite coating with high amorphous volume was prepared by high velocity arc spraying on the 45 steel. The microstructure, macroscopic corrosion performance and microzone corrosion performance of the composite coating was investigated. XRD, SEM with EDS and TEM were applied to confirm that the gray zone of the composite coating microstructure was the amorphous enrichment zone. It was found by the scanning Kelvin probe microscopy (SKPM) that the corrosion failure order of each phase of the composite coating was arranged in order of the aluminum rich phases, the oxidation phases and the amorphous phase. The microhardness of the composite coating was about 364 HV0.1 which was greater than that of 45 steel. The EIS fitting results showed that the charge transfer resistance of the composite coating is 2~4 times of the aluminum coating and 45 steel. It has two time constants in the spectrum. The corrosion failure behavior of the composite coating in the low frequency was controlled by the diffusion process, which was related to the accumulation and diffusion of the corrosion products. The potentiodynamic polarization curves fitting results indicated that the self-corrosion potential of the composite coating was higher than those of the aluminum coating and 45 steel. And the self-corrosion current density of the composite coating was about 1.08 μA/cm2, which was 7/100 and 1/3 of that of the aluminum coating and 45 steel, respectively. According to the corrosion morphology of the composite coating, there was no obvious pitting. A large number of NaCl crystals were attached to the surface of the aluminum rich phase region as the preferred corrosion zone. But the surface of the amorphous enrichment zone was smooth. At the same time, the corrosion pits, micro-cracks and pitting enrichment occurred on the surface of the composite coating, which was mainly related to the effects of Cl- erosion and swelling.

Key words:  aluminum base amorphous and nanocrystalline composite coating      microzone corrosion      corrosion resistance      surface protection for steel structure     
Received:  27 November 2017     
ZTFLH:  TG174.4  
Fund: Supported by National Natural Science Foundation of China (Nos.51505500 and 51375492)

Cite this article: 

Xiubing LIANG, Jianwen FAN, Zhibin ZHANG, Yongxiong CHEN. Microstructure and Corrosion Properties of Aluminum Base Amorphous and Nanocrystalline Composite Coating. Acta Metall Sin, 2018, 54(8): 1193-1203.

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Fig.1  XRD spectra of the Al base amorphous and nanocrystalline Al-Ni-Zr composite coating (a) and Al coating (b)
Fig.2  Cross-sectional SEM images of the Al-Ni-Zr composite coating (a) and Al coating (b)
Fig.3  High magnified cross-sectional SEM image of the Al-Ni-Zr composite coating
Zone Al Ni Zr O
I 16.28 21.75 25.84 36.13
II 68.60 19.55 6.01 5.84
III 74.67 15.76 5.81 3.76
IV 86.47 7.17 2.25 4.11
Table 1  SEM-EDS analysis of the Al-Ni-Zr composite coating in Fig.3 (atomic fraction / %)
Fig.4  TEM images of the Al-Ni-Zr composite coating and corresponding SAED patterns (insets)(a) amorphous phase(b) amorphous and nanocrystalline phases
Zone Al Ni Zr
I 74.30 18.58 7.12
II 88.79 8.48 2.73
III 100.00 - -
Table 2  TEM-EDS analysis of the Al-Ni-Zr composite coating in Fig.4 (atomic fraction / %)
Fig.5  Vickers hardness profile across interface of the Al-Ni-Zr composite coating
Fig.6  Potentiodynamic polarization curves of the Al-Ni-Zr composite coating, Al coating and 45 steel in 3.5%NaCl solution
Sample Ecorr / V icorr / (μAcm-2) Rp / (kΩcm-2) βA / mV βC / mV
Al-Ni-Zr coating -0.645 1.08 24.51 108.0 140
Al coating -1.297 15.46 3.99 1167.5 162
45 steel -0.712 3.72 7.62 76.1 458
Table 3  Potentiodynamic polarization curves fitting results
Fig.7  Nyquist curves of the Al-Ni-Zr composite coating, Al coating and 45 steel in 3.5%NaCl solution
Fig.8  Corrosion morphologies of 45 steel (a), Al coating (b), Al-Ni-Zr composite coating (c) and composite coating after ultrasonic cleaning (d) in 3.5%NaCl solution
Fig.9  BE-SEM image (a) and element distribution maps of Al (b), Ni (c), Zr (d) and O (e) of Al-Ni-Zr composite coating
Fig.10  Surface potential distribution map (a) and actual surface potential along the white line in Fig.10a (b) of Al-Ni-Zr composite coating
Fig.11  Corrosion failure morphologies of Al-Ni-Zr composite coating in 3.5%NaCl solution(a) NaCl crystal regular attachment (Arrows show the NaCl crystals, inset shows the enlarged view)(b) micro-cracks (Inset shows the enlarged view)(c) crack propagation(d) corrosion pits (Inset shows the enlarged view after ultrasonic cleaning)(e) pitting enrichment
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