Salt spray corrosion test of micro-plasma oxidation ceramic coatings on Ti alloy

Ceramic coatings were prepared on Ti-6Al-4V alloy in NaAlO2 solution by micro-plasma oxidation （MPO）. The salt spray tests of the coated samples and the substrates were carded out in a salt spray test machine. The phase composition and surface morphology of the coatings were investigated by XRD and SEAM. Severe corrosion occurred on the substrate surface, while there were no obvious corrosion phenomena on the coated samples. The coatings were composed of Al2TiO5 and a little α-Al2O3 and mille TiO2, and the salt spray test did not change the composition of the coatings. The weight loss rate of the coatings decreased with increasing MPO time because of the increase in density and thickness of the coatings. The surface morphology of the coatings was influenced by salt spray corrosion test. Among the coated samples, the coating prepared for 2 h has the best corrosion resistance under salt spray test.

The Surface Morphologies and Spectroscopy Analysis of VC Coatings on the Substrate of Cr12MoV Prepared by TD Process after Salt Spray

The normal temperature corrosion of VC coating on the substrate of Cr12MoV prepared by TD process was tested in 5% NaCl aqueous solution, its surface morphologies and corrosion components after salt spray were observed with SEM and EDS, respectively, and the effects of salt spray on micro-structures of VC coating were analyzed. Moreover, the invalidation mechanism of VC coating after salt spray and its effect on substrate material were discussed. The experimental results shown that the uniformity and integrity of VC coating surface are destroyed by salt spray for 120 h, a large number of the pits are produced on the coating surface, and the coating falls off, which speeds corrosion breakage of its substrate; the oxidated film on its surface becomes rougher, broken and discontinuous, and falls off easily, which reduce the ability of resistance salt spray; the failure modes of VC coating after salt spray are expressed with falling off of oxidated film, stress concentration and pore effect and so on, the corrosion breakage of oxidated film is the corrosion result of deoxidization corrosion from oxygen and HCl produced by NaCl and vapor.

Effect of Salt Spray Corrosion on Tribological Properties of HVOF Sprayed NiCr-Cr3C2 Coating with Intermediate Layer

The objective of the present work was to determine the influence of the neutral salt spray corrosion on the wear resistance of HVOF sprayed NiCr-Cr3C2 coating with intermediate layer. Ni-Zn-Al2O3 coatings as interlayers were prepared by low pressure cold spray（LPCS） between NiCr-Cr3C2 cermet coatings to form a sandwich structure to enhance the corrosion resistance properties. The tribological properties were examined using the UMT-3 fricition and wear tester by line-contact reciprocating sliding under dry and salt spray one week corrosion. The morphology, element distribution, and phase compositions of the coating and worn sufaces were analyzed by using scanning electron microscopy, energy dispersive spectrometry, and X-ray diffraction respectively. The corrosion behavior of the coating was studied by the open-circuit potential, the electrochemical impedance spectroscopy, potentiodynamic polarization, and salt spray corrosion methods. It is found that the sandwich structured coating has better corrosion resistance than the single layer coating. The results show that under dry wear conditions, the wear mechanism is abrasive and adhesive wear, whereas under salt spray corrosion conditions it becomes corrosion wear. The friction coefficient of the sandwich structured coating after salt spray corrosion is slightly lower than the dry friction coefficient, but the weight of the wear loss is lower than that under dry condition.

CORROSION FATIGUE OF HSLA STEELS IN SALT SPRAY

The corrosion fatigue propagation behaviour of high strength low alloy Cr-Ni and Si-Mn steels has been investigated in 3.5 %NaCl solution spryly at the frequencies of 0.1 and 5.5 Hz. It was shown that the fatigue crack initiation resistances of the two steels are significantly re- duced in salt spray;the fatigue crack growth rates of steels increase with the decrease of fre- quency and are much higher in salt spray than in air within low ΔK range.A critical stress in- tensity factor was observed for each steel and the crack growth stoppage will occur if the ΔK values are lower than it.It was found that the active dissolution makes great contribution to the fatigue crack growth within low ΔK range.

Composites Based on GM(1,1)-Markov in the Salt Spray Corrosion Environment

This study was designed to solve the problem of magnesium hazards due to potash extraction in the salt lake region.Using basalt fiber(BF)as the reinforcement material and magnesium oxychloride cement(MOC)as the gelling material,a BF/MOC composite material was prepared.Firstly,the effect of BF addition content on the basic mechanical properties of the composites was investigated.Then,through the salt spray corrosion test,the durability damage deterioration evaluation analysis was carried out from both macroscopic and microscopic aspects using mass change,relative dynamic modulus of elasticity(RDME)change,SEM analysis and FT-IR analysis.Finally,a GM(1,1)-Markov model was established to predict the durability life of composite materials by using durability evaluation indicators.The results show that:when the BF content is 0.10%(by volumetric content),the composites have the best mechanical properties and resistance to salt spray corrosion.However,when the volume of BF content exceeds 0.10%,a large number of magnesium salt crystallization products are observed from the microscopic point of view,and the corrosion of the main strength phase of MOC is more serious.The prediction results of the GM(1,1)-Markov model are highly identical with the raw data.In addition,using the change of RDME as a predictor,RDME is more sensitive to environmental factor compared to the change of mass.Predictions using the change of RDME as a threshold indicate that MOC-BF0.10 has the longest durability life,which is 836 days.The model is important to promote the application of MOC composites in the salt lake region and to promote the healthy development of green building materials.

Fire and Corrosion Resistances of Intumescent Nano-coating Containing Nano-SiO_2 in Salt Spray Condition

The nano-concentrates and flame retardant nano-coating were prepared in thhis study. The effect of nano-SiO2 on the corrosion resistance and fire resistance of ammonium polyphosphate-pentaerythritol-melamine （APP- PER-MEL） coating was investigated by differential thermal analysis （DTA）, scanning electron microscopy （SEM）, effective thermal conductivity （λ/d）, X-ray photoelectron spectroscopy （XPS） and fire protection test. The chemical action and endothermic effect of ammonium polyphosphate, pentaerythritol and melamine in traditional flame retardant coating were damaged by salt spray condition, whereas the flame-retardant additives in the nano-coating demonstrated the good chemical interaction in salt spray condition. The uniformly dispersed nano-SiO2 particles could improve corrosion resistance of the coating, and hence nano-coating could remain the good fire-resistant properties even after 500 h salt spray test.

Initial corrosion behavior and mechanism of 7B04 aluminum alloy under acid immersion and salt spray environments

The initial corrosion behavior and mechanism of 7B04 aluminum alloy under acid immersion and salt spray environments(pH=3.5)are studied by Scanning Electron Microscope(SEM),optical microscope,Fourier Transform Infrared Spectroscopy(FT-IR),X-Ray Diffraction(XRD),potentiodynamic polarization,Electrochemical Impedance Spectroscopy(EIS),and Scanning Kelvin Probe(SKP).The results show that pitting corrosion occurs at the initial corrosion stage,and the potential difference between the second phase particles is the main cause of pitting.Pitting pits on different locations gradually expand and coalesce with the proceeding of corrosion.The main components of corrosion products are Al_(2)O_(3),Al(OH)_(3),and AlCl_(3),and the generation rate of the corrosion product layer under the salt spray environment is larger than that under acid immersion environment.Under both environments,the Volta potential distribution first disperses and then concentrates,while the charge transfer resistance first decreases and then increases with the corrosion time.The Volta potential gradually shifts in a positive direction,indicating that corrosion products have an inhibitory effect on corrosion.After the same corrosion time,the corrosion product layer resistance and the expectation of the Volta potential of the salt spray sample are higher than those of the immersion sample.Comparatively,the corrosion current density for the salt spray sample is significantly lower than the immersion sample,which indicates that the thicker the corrosion product layer,the stronger the inhibition of corrosion reaction.

The corrosion behaviors of Mg-7Gd-5Y-1Nd-0.5Zr alloy under(NH4)_(2)SO_(4),NaCl and Ca(NO_(3))_(2)salts spray condition

The corrosion behaviors of Mg–7Gd–5Y–1Nd–0.5Zr alloys after T5 treatment under(NH4)_(2)SO_(4),NaCl and Ca(NO_(3))_(2)salt spray condition were investigated by weight loss rates,residual mechanical properties,scanning electron microscope(SEM),X-ray Diffraction(XRD)and potentiodynamic polarization tests.The corrosion degree of Mg–7Gd–5Y–1Nd–0.5Zr alloys in Ca(NO_(3))_(2)salt spray was very shallow by corrosion morphology and the corrosion route was extended along the surface in texture-like shape,while the alloy in NaCl and(NH4)_(2)SO_(4)salt spray were major local corrosion and there were serious corrosion pits on the surface.The weight loss rates in(NH4)_(2)SO_(4),NaCl and Ca(NO_(3))_(2)salt spray was respectively 0.4147,0.1618 and 0.0725 mg/(cm2 d−1).The results of residual mechanical properties indicated that the corrosion order in salts spray of Mg–7Gd–5Y–1Nd–0.5Zr alloys is NH4SO4>NaCl>Ca(NO_(3))_(2),which was consistent with the results of potentiodynamic polarization tests.The type of the salts will play a vital role in the initiation of the corrosion of EW75 alloy when they are used in the atmosphere environments.Inorganic salts with the smaller PH value after dissolution will have a stronger impact on the corrosion of EW75 magnesium alloys.

Electrochemical corrosion failure mechanism of M152 steel under a salt-spray environment

The corrosion failure mechanism of M152 was studied using the neutral salt-spray test to better understand the corrosion behavior of 1Cr12Ni3Mo2VN（M152）, provide a basis for the optimization of material selection, and prevent the occurrence of failure. Moreover, the mechanism was investigated using the mass loss method, polarization curves, electrochemical impedance spectroscopy（EIS）, stereology microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy（EDS）. The results show that M152 steel suffers severe corrosion, especially pitting corrosion, in a high-salt-spray environment. In the early stage of the experiment, the color of the corrosion products was mainly orange. The products then gradually evolved into a dense, brown substance, which coincided with a decrease of corrosion rate. Correspondingly, the EIS spectrum of M152 in the late test also exhibited three time constants and presented Warburg impedance at low frequencies.

Effects of rare earths on the microarc oxidation of a magnesium alloy

The effects of rare earths on the properties of the microarc oxidation（MAO） coating on a magnesium alloy were investigated by means of scanning electron microscopy（SEM）,energy dispersive X-ray spectroscopy（EDS）,and electrochemistry methods.The results show that a nice and compact MAO coating was successfully obtained when the magnesium alloy was treated in nitrate solutions as the pre-treatment of MAO.However,the MAO was not successfully completed for the silicate electrolytes with the addition of rare earths.After the magnesium alloy being treated by rare earth nitrate,the obtained MAO coating has advantages such as uniform distribution of thickness,improved corrosion resistance,and nice-uniform surface,as compared with the untreated magnesium alloy.In addition,the time of non-ESP,the voltage and current density of the MAO process obviously decrease.Cerium oxide doped on the surface of the magnesium alloy can significantly improve the corrosion resistance of the MAO coating and decrease the current density of the MAO process,as compared with lanthanum oxide,whereas the doped rare earths have no significant effect on the components of the MAO coating.

Comparison of corrosion behavior of ZL104 alloy at as-cast and heat treatment states

The corrosion behavior of ZL104 alloy at different states (as-cast and heattreatment) in salt spray corrosion (SSC) was studied. The results show that the sample treated afterrefinement and modification has the least corrosive resistance compared with the sample bearingas-cast structure at the beginning of the corrosion. As the corrosion process continued, however,the trend reversed itself. After 44 h continuous corrosion, the corrosive rates of all samples tendto be stable. After experiments, the sample bearing as-cast structure had the most corrosiveproducts on the surface whereas the sample being refined and modified had the least products. TheFourier transformation infrared spectroscopy (FTIR) analyses of the corrosion products show thatthese products are composed of hydroxyl-containing substances.

Laboratory and field testing of bolting systems subjected to highly corrosive environments

The capacity of ground support components which have been affected by corrosion is reduced and may ultimately lead to dynamic failure of the component and the strata. In order to maintain an effective,long-term ground support system, significant campaigns of rehabilitation are often required in corrosion affected areas which also expose the workers to hazardous conditions. The most common corrosion protection for steel ground support utilises sacrificial systems such as galvanising. Galvanising has previously been proven to be susceptible to some corrosion processes. Stainless steel is the most effective in resistance to corrosion, but can be cost prohibitive, and its mechanical properties often make it unsuited to use in ground support components. Providing an outer protective plastic coating to bolts has proven to be an effective means of protecting the inner steel bar from corrosion. However, these support systems tend to be susceptible to coating damage, and require post cement grouting to provide full encapsulation. In comparison to a standard bolt/resin system, they can be slow to install and expensive.These systems have also been shown to reduce overall load transfer performance of the bolting system. In order to provide a higher level of corrosion protection whilst maintaining current installation practices and bolting cycle times, Minova has developed the Enduro^(TM)steel ground support range. The Enduro^(TM) range consists of standard Minova steel ground support components which have been treated with a unique coating process. The Enduro^(TM)coating has been tested in the harshest of conditions, in laboratory controlled conditions and in underground trials. It has been proven to effectively resist or completely eliminate the formation of corrosion, even in the most aggressive environments. This paper explains the process and provides the details of the laboratory and underground corrosion performance testing carried out on Enduro^(TM)ground support products.

Galvanic Corrosion of Magnesium Alloy and Aluminum Alloy by Kelvin Probe

Galvanic corrosion on samples of AZ91D magnesium alloy coupled with 2A12 aluminum alloy during neutral salt spray test was investigated.The variations of the surface potential were measured using scanning kelvin probe（SKP）.The results showed that galvanic effect on the corrosion of AZ91D magnesium alloy is closely related to the potential difference between the anodic and cathodic materials.In the initial period,corrosion only occurred in a narrow area at the coupling interface because of the limited distance galvanic current.Then,the corrosion rate of 2A12 aluminum alloy was accelerated due to its poor stability in strong alkali environment,which was attributed to the strong alkalization caused by the corrosion of AZ91D magnesium alloy.With the increase of the potential of 2A12 aluminum alloy as a result of the continuous covering of corrosion products,the potential difference between the two materials was enlarged,which enhanced the galvanic corrosion.

Corrosion of Carbon Steel under Epoxy-varnish Coating Studied by Scanning Kelvin Probe

The corrosion behavior of partly coated carbon steel was investigated by salt spray test and scanning Kelvin probe （SKP） in order to understand the long-term corrosion behavior of coated carbon steel in marine atmosphere environment. The localized corrosion was accurately characterized by SKP in both coated and uncoated regions. The SKP results showed that Volta potential varied with the test time, and the more the corrosion products, the more positive the potential. The borderline between coated and uncoated regions of partly coated steel shifted towards the coated side with the increasing of test time. The coating disbonding rate could be determined according to the shift of potential borderline measured by SKP. The corrosion mechanism of partly coated steel in NaCl salt spray was discussed according to the potential maps and corrosion morphologies.

Improvement the Corrosion Resistance for the Galvanized Steel by Adding Sn

The chemical composition of the zinc bath can strongly influence on the hot-dip galvanized coatings. In this work, the effects of tin addition on the surface morphology, and the corrosion resistance of hot-dip galvanized steel were investigated. The corrosion behavior of steel samples galvanized with zinc and Zn-Sn alloys containing different wt% Sn was analyzed by various corrosion tests such as potentiodynamic polarization Tafel lines and electrochemical impedance spectroscopy (EIS) techniques. Salt spray test was employed in order to study the corrosion products of the specimens. Surface morphology, the composition of coating layers and nature of the corrosion products were also investigated using field emission scanning electron microscopy (FE-SEM), energy dispersive X-ray analysis (EDX) and X-Ray diffraction (XRD) techniques, respectively. The results indicated that the addition of small amounts of Sn (0.1 wt%) to the molten zinc galvanizing bath can improve the corrosion resistance of hot-dip galvanized steel.

Corrosion mechanism investigation of TiN/Ti coating and TC4 alloy for aircraft compressor application

It is imperative to develop multifunctional erosion and corrosion resistant coatings for compressor blades of aircraft engines in harsh environment.PVD(Physical Vapor Deposition)technology has the advances in processing erosion-resistant coatings;however,the performance of PVD coatings to combat corrosion depends on various coating defects.Determining and comparing the corrosion performances of PVD TiN/Ti coating and uncoated TC4 alloy was the main objective of present work.The 960 h salt spray corrosion and 116 h hot corrosion tests were conducted to simulate the grounding and working environments of the aircraft compressors.The corrosion mechanisms due to the coating defects such as pinhole,columnar boundary and large grain were analyzed based on the OM,Confocal microscope,electrochemical measurements,SEM,XRD and EDS results.Owing to the disordered state associated with the columnar boundary and the coating defect,nitrogen could be easily replaced by oxygen in the hot corrosion process,these structures were channels for fast diffusion of oxygen.Moreover,the Gibbs energy changes of Ti oxidation and TiN oxidation were thermodynamically calculated according to the working condition of aircraft compressors,and considerable research effort was focused on mapping out the phase diagram of Ti,TiN and high pressure gases.The findings of this research can provide insights into developing multifunctional coatings for future aircraft engines.

Enhanced Anticorrosion Properties of Epoxy Coatings from Al and Zn Based Pigments

Anticorrosion epoxy coatings from Al and Zn based pigments were synthesized by adjusting their volume ratios, aiming at their increasing anticorrosion performances. The anticorrosion properties were examined via elec- trochemical impedance spectroscopy, Tafel polarization curve analysis and salt spray test. The coating morphologies before and after the salt spray tests were studied via scanning electron microscopy（SEM）. The elemental and chemical compositions of the corroded surfaces of the coatings were analyzed by means of X-ray photoelectron spectroscopy（XPS）. The results indicate that the coating composed of Al/Zn at 10：1（volume ratio） displays the maximum anticorrosion performances, which are superior to those of pristine Al or Zn based pigment.

Influence of Nano-Al Concentrates on the Corrosion Resistance of Epoxy Coatings

A two-stage process was used to produce nano-composite epoxy coatings. The first step involved preparing nano-AI concentrates with high concentration and low viscosity, and the second step produced nano- composite epoxy coatings by mixing the nano-AI concentrates and epoxy resin. Later, the coating was examined with immersion and salt spray tests. The coatings were characterized by electrochemical impedance spectroscopy （EIS）, scanning electron microscopy （SEM） and X-ray photoelectron spectroscopy （XPS）. The results showed that the 5% nano-AI significantly improves the corrosion resistance of the coatings. There are two effects of nano-AI on the coating. Nano-AI is corroded initially to protect the substrate from corrosion, and then the aluminum oxide and aluminum hydroxide were produced after corrosion of nano-AI, which hindered the transmission of corrosion fluid into the coatings.