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
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.
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.
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
[1]
IABSE, translated by Shi G. Use and Application of High-Performance Steels for Steel Structures [M]. Beijing: China Architecture & Building Press, 2010: 1(国际桥梁与结构工程协会编著, 施刚译. 高性能钢材在钢结构中的应用 [M]. 北京: 中国建筑工业出版社, 2010: 1)
[2]
Hou B R, Zhang D, Wang P.Marine corrosion and protection: Current status and prospect[J]. Bull. Chin. Acad. Sci., 2016, 31: 1326(侯保荣, 张盾, 王鹏. 海洋腐蚀防护的现状与未来[J]. 中国科学院院刊, 2016, 31: 1326)
[3]
Cao H T, Li X T.Corrosion protection requirements and technical measures of fasteners based on the marine environment[J]. Surf. Technol., 2013, 42(1): 105(曹宏涛, 李雪亭. 基于海洋环境的紧固件腐蚀防护要求及技术措施[J]. 表面技术, 2013, 42(1): 105)
[4]
Zhang Q X, Xu M, Wang X T, et al.Research progress of heavy-duty anticorrosive coating applied on marine steel structure[J]. Equip. Environ. Eng., 2015, 12(4): 60(张巧霞, 许沫, 王秀通等. 重防腐涂料在海洋工程钢结构中的研究进展[J]. 装备环境工程, 2015, 12(4): 60)
[5]
Tachibana K, Morinaga Y, Mayuzumi M.Hot dip fine Zn and Zn-Al alloy double coating for corrosion resistance at coastal area[J]. Corros. Sci., 2007, 49: 149
[6]
Azaroual M A, Ei Harrak E F, Touir R, et al. Synergistic corrosion protection for galvanized steel in 3.0% NaCl solution by sodium gluconate and cationic surfactant[J]. J. Mol. Liq., 2016, 220: 549
[7]
Yaro A S, Khadom K W, Khadom A A.Study for prevention of steel corrosion by sacrificial anode cathodic protection[J]. Theor. Found. Chem. Eng., 2013, 47: 266
[8]
Lee H S, Singh J K, Park J H.Pore blocking characteristics of corrosion products formed on aluminum coating produced by arc thermal metal spray process in 3.5wt.% NaCl solution[J]. Construc. Build. Mater., 2016, 113: 905
[9]
Lou M, Hu Y L, Qiang W J, et al.Application of high velocity arc sprayed coatings in preventing steel structures from corrosion[J]. Mater. Prot., 2011, 44(3): 54(楼淼, 胡永乐, 强文江等. 高速电弧喷涂层在钢结构防腐蚀中的作用及应用现状[J]. 材料保护, 2011, 44(3): 54)
[10]
Liang X B, Liu Y, Chen Y X, et al.Integrated technology of materials preparation and formation based on high velocity arc spraying[J]. J. Acad. Armored Force Eng., 2008, 22(6): 79(梁秀兵, 刘燕, 陈永雄等. 基于高速电弧喷涂的材料制备与成型一体化技术[J]. 装甲兵工程学院院报, 2008, 22(6): 79)
[11]
Liang X B, Bai J Y, Cheng J B, et al.Study on amorphous and nanocrystalline composite coatings prepared by arc spraying process[J]. Thermal Spray Technol., 2009, 1(2): 23(梁秀兵, 白金元, 程江波等. 电弧喷涂非晶纳米晶复合涂层材料研究[J]. 热喷涂技术, 2009, 1(2): 23)
[12]
Liu Q, Xiao H Q, Ma S N.Progress of arc spraying on anticorrosion coating[J]. Surf. Technol., 2004, 33(5): 15(刘谦, 肖宏清, 马世宁. 电弧喷涂防腐蚀涂层研究[J]. 表面技术, 2004, 33(5): 15)
[13]
Li G H, Pan S P, Qin J Y, et al.Insight into thermodynamics and corrosion behavior of Al-Ni-Gd glassy alloys from atomic structure[J]. Corros. Sci., 2013, 66: 360
[14]
Jinal R, Raja V S, Gibson M A, et al.Effect of annealing below the crystallization temperature on the corrosion behavior of Al-Ni-Y metallic glasses[J]. Corros. Sci., 2014, 84: 54
[15]
Lahiri D K. Gill P, Scudino S, et al.Cold sprayed aluminum based glassy coating: Synthesis, wear and corrosion properties[J]. Surf. Coat. Technol., 2013, 232: 33
[16]
Tan C L, Zhu H M, Kuang T C, et al.Laser cladding Al-based amorphous-nanocrystalline composite coatings on AZ80 magnesium alloy under water cooling condition[J]. J. Alloys Compd., 2017, 690: 108
[17]
Henao J, Concustel A L, Cano I G, et al.Novel Al-based metallic glass coatings by cold gas spray[J]. Mater. Des., 2016, 94: 253
[18]
Liang X B, Zhang Z B, Chen Y X, et al.Study of Al-based amorphous and nanocrystalline composite coating[J]. Acta Metall. Sin., 2012, 48: 289(梁秀兵, 张志彬, 陈永雄等. 铝基非晶纳米晶复合涂层研究[J]. 金属学报, 2012, 48: 289)
Luo D W, Li C B, Chen W W.Recent progress for metallic glass coatings[J]. Mater. Rev., 2015, 29(3): 88(罗大为, 李聪勃, 陈为为. 非晶态合金涂层的研究进展[J]. 材料导报, 2015, 29(3): 88)
[21]
Verdon C, Karimi A, Martin J L.A study of high velocity oxy-fuel thermally sprayed tungsten carbide based coatings. Part 1: Microstructures[J]. Mater. Sci. Eng., 1998, A246: 11
[22]
Liu C, Zhao W M, Ai H, et al.Electrochemical corrosion behaviors of arc-sprayed aluminum coating[J]. J. Chin. Soc. Corros. Prot., 2011, 31: 62(刘存, 赵卫民, 艾华等. 电弧喷涂铝涂层的腐蚀电化学行为[J]. 中国腐蚀与防护学报, 2011, 31: 62)
[23]
Cao C N.Principles of Electrochemistry of Corrosion [M]. 3rd Ed., Beijing: Chemical Industry Press, 2008: 255(曹楚南. 腐蚀电化学原理 [M]. 第3版. 北京: 化学工业出版社, 2008: 255)
[24]
Wang X F, Wu X Q, Lin J G, et al.The influence of heat treatment on the corrosion behaviour of as-spun amorphous Al88Ni6La6 alloy in 0.01M NaCl solution[J]. Mater. Lett., 2007, 61: 1715
[25]
Wu X Q, Ma M, Chan C G, et al.Comparative study on thermodynamical and electrochemical behavior of Al88Ni6La6 and Al86Ni6La6Cu2 amorphous alloys[J]. J. Rare Earths, 2007, 25: 381
[26]
Roy A, Mandhyan A K, Sahoo K L, et al.Electrochemical response of amorphous and devitrified Al-Ni-La-X (X=Ag, Cu) alloys[J]. Mater. Corros., 2015, 60: 431
[27]
Gupta R K, Das H, Pal T K.Influence of processing parameters on induced energy, mechanical and corrosion properties of FSW butt joint of 7475 AA[J]. J. Mater. Eng. Perform., 2012, 21: 1645
[28]
Huang L C, Gu A, Liu H C, et al.Corrosion failure of aluminum alloy parts on airplane used in marine environment[J]. J. Beijing Univ. Aeron. Astron., 2008, 34: 1217(黄领才, 谷岸, 刘慧丛等. 海洋环境下服役飞机铝合金零件腐蚀失效分析[J]. 北京航空航天大学学报, 2008, 34: 1217)
[29]
Dong C F, Sheng H, An Y H, et al.Local electrochemical behavior of 2A12 aluminium alloy in the initial stage of atmospheric corrosion under Cl- conditions[J]. J. Univ. Sci. Technol. Beijing, 2009, 31: 878(董超芳, 生海, 安英辉等. Cl-作用下2A12铝合金在大气环境中腐蚀初期的微区电化学行为[J]. 北京科技大学学报, 2009, 31: 878)
