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Acta Metall Sin  2019, Vol. 55 Issue (10): 1338-1348    DOI: 10.11900/0412.1961.2019.00047
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Corrosion Behavior of Al(Y)-30%Al2O3 Coating Fabricated by Low Pressure Cold Spray Technology
BAI Yang1,2,WANG Zhenhua3,LI Xiangbo3,LI Yan1()
1. School of Materials Science and Engineering, China University of Petroleum, Qingdao 266580, China
2. State Key Laboratory of Marine Coatings, Marine Chemical Research Institute Co. , Ltd. , Qingdao 266071, China
3. State Key Laboratory for Marine Corrosion and Protection, Luoyang Ship Material Research Institute, Qingdao 266237, China
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Abstract  

Low-pressure cold spray technology (LPCS) is a new type of surface treatment technology. Compared with the conventional thermal sprayed aluminum coating, the LPCS aluminum coating has the advantages of a low degree of oxidation, high density and good resistance to uniform corrosion. However, the inert aluminum coating is not stable in marine environment, it is prone to localized corrosion, which leads to coating failure. Therefore, in order to solve the key common problems of corrosion, which are common in offshore oil and gas equipments, such as deep-sea drilling rigs, platforms and on-line storage and offloading devices, the corrosion resistance performance of the low pressure cold sprayed Al(Y)-30%Al2O3 (volume fraction) composite coatings were carried out. In this work, Al(Y)-30%Al2O3 composite coating with different rare earth elements (Y) was prepared on the Q235 carbon steel substrate by low pressure cold spray technology, aiming to improve the local corrosion resistance performance of aluminum coating in marine environment. The effects of Y addition on the corrosion behavior of Al(Y)-30%Al2O3 coating with different Y contents (mass fraction: 0.05%, 0.1%, 0.2%, 0.5%) were studied by electrochemical measurements and microstructural analysis. The corrosion mechanism of the composite coating was elucidated. The results show that the addition of an appropriate amount of Y element is very important to improve the corrosion resistance of the coating; whether the addition amount of Y is too low or too high, the improvement can be negligible or even negative; the optimal amount of Y is 0.2% (mass fraction), by which the corrosion resistance of the coating is one order of magnitude higher than that of Al-30%Al2O3 coating; the corrosion process of Al(Y)-30%Al2O3 coating includes four stages: the surface uniform corrosion, the interfacial erosion-infiltration diffusion, the localized corrosion and the corrosion inhibition.

Key words:  low pressure cold spray      aluminum matrix composite coating      electrochemical impedance spectroscopy      corrosion behavior     
Received:  22 February 2019     
ZTFLH:  TG174  
Fund: Supported by Fundamental Research Funds for the Central Universities(18CX05021A);Key Research and Development Program of Shandong Province of China(2017GHY15108);Postdoctoral Applied Research Project of Qingdao of China
Corresponding Authors:  Yan LI     E-mail:  yanlee@upc.edu.cn

Cite this article: 

BAI Yang, WANG Zhenhua, LI Xiangbo, LI Yan. Corrosion Behavior of Al(Y)-30%Al2O3 Coating Fabricated by Low Pressure Cold Spray Technology. Acta Metall Sin, 2019, 55(10): 1338-1348.

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00047     OR     https://www.ams.org.cn/EN/Y2019/V55/I10/1338

Fig.1  Surface morphologies of the Al(Y)-30%Al2O3 (volume fraction) coatings with 0.05% (a), 0.1% (b), 0.2% (c) and 0.5% (d) Y (mass fraction)
Fig.2  Cross-sectional morphologies of the Al(Y)-30%Al2O3 coatings with 0.05% (a), 0.1% (b), 0.2% (c) and 0.5% (d) Y
Fig.3  Cross-sectional SEM images of the etched Al(Y)-30%Al2O3 coatings without (a) and with (b) 0.1%Y (Inset shows the EDS analysis)
Fig.4  Open-circuit potential (Eocp) vs time (t) curves for the Al(Y)-30%Al2O3 coatings with different contents of Y
Fig.5  Nyquist plots for the Al(Y)-30%Al2O3 coatings with 0.05% (a), 0.1% (b), 0.2% (c) and 0.5% (d) Y at different immersion time in seawater
Fig.6  Bode plots for the Al(Y)-30%Al2O3 coatings with 0.05% (a), 0.1% (b), 0.2% (c) and 0.5% (d) Y at different immersion time in seawater (f — frequency)
Fig.7  Nyquist diagram (a) and Bode plots (b) of the Al(Y)-30%Al2O3 coatings with different contents of Y after 720 h immersion in seawater
Fig.8  Potentiodynamic polarization curves of the Al(Y)-30%Al2O3 coatings with different contents of Y after 720 h immersion in seawater

Mass fraction of Y

%

Ecorr (vs SCE)

V

icorr

μA·cm-2

βa

mV·dec-1

βc

mV·dec-1

0-0.78571.758998.13-132.77
0.05-0.73340.587954.06-117.82
0.1-0.74320.3719130.59-131.46
0.2-0.76970.3473158.16-126.88
0.5-0.76641.203970.97-122.85
Table 1  Results from the potentiodynamic polarization test of the Al(Y)-30%Al2O3 (volume fraction) coatings with different contents of Y after 720 h immersion in seawater
Fig.9  XRD spectra of the Al(Y)-30%Al2O3 coatings after 1440 h immersion in seawater
Fig.10  Element distributions of the corrosion surface for Al(Y)-30%Al2O3 coatings before (a) and after (b) 1440 h immersion in seawater
Fig.11  FTIR of corrosion product on the Al(Y)-30%Al2O3 coating surfaces after 1440 h immersion in seawater
Fig.12  SEM images (a, c, e, g) and high magnified images of the selected area (b, d, f, h) of Al(Y)-30%Al2O3 coatings with 0.05% (a, b), 0.1% (c, d), 0.2% (e, f) and 0.5% (g, h) Y after 1440 h immersion in seawater
Fig.13  Schematics of the proposed corrosion mechanism model of LPCS Al(Y)-30%Al2O3 composite coatings
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