A Comprehensive Review of Corrosion Resistance of Thermally-Sprayed and Thermally-Diffused Protective Coatings on Steel Structures

Galedari, S. Abuali; Mahdavi, Amirhossein; Azarmi, Fardad; Huang, Ying; McDonald, André

doi:10.1007/s11666-019-00855-3

Cited by 80 publications

(35 citation statements)

References 159 publications

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“…Li et al confirmed that the corrosion resistance of Cr 3 C 2 -based coatings is the result of oxide formation, such as Cr 2 O 3 and Ni 2 O 3 , protecting the substrate (Ref 8 ). The corrosion resistance of WC-10Co-4Cr, as widely reported, is improved by the Cr content in solid solution (Ref 8 , 15 , 24 , 25 ). Hong et al studied the electrochemical behavior of WC-10Co-4Cr in 3.5% NaCl, reporting that aside from the Cr content, the amorphous structure of the coating enhanced the ability to form dense and protective oxide films.…”

Section: Introductionmentioning

confidence: 63%

“…The higher dissolution of the WC-12Co and WC-10Ni cermets can be explained by their corrosion mechanisms. As widely reported, WC-based coatings undergo micro-galvanic corrosion between the metallic matrix (Ni, Co) and the ceramic phase (WC), in which the metallic matrix acts as the anode and is preferentially corroded, maintaining the surface of these cermets under active dissolution conditions (Ref 15 - 18 , 24 , 25 ). This can be related to the more negative corrosion potentials, ranging from − 372 mV versus SCE (WC-10Ni) to − 414 mV versus SCE (WC-12Co).…”

Section: Resultsmentioning

confidence: 97%

“…It is widely reported that WC-Co and WC-Ni coatings tend to have low corrosion resistance as a result of micro-galvanic cells formed between the ceramic phase and the metal binder (Ref 15 - 18 ). Many authors have found that the formation of porous non-protective cobalt oxide (CoO) leads to low corrosion resistance of WC-Co coatings (Ref 8 , 15 , 19 ). Nevertheless, Cr 3 C 2 coatings with a matrix of NiCr and Ni tend to have high corrosion resistance in a variety of corrosive media (Ref 8 , 15 , 20 - 23 ).…”

Section: Introductionmentioning

confidence: 99%

“…Many authors have found that the formation of porous non-protective cobalt oxide (CoO) leads to low corrosion resistance of WC-Co coatings (Ref 8 , 15 , 19 ). Nevertheless, Cr 3 C 2 coatings with a matrix of NiCr and Ni tend to have high corrosion resistance in a variety of corrosive media (Ref 8 , 15 , 20 - 23 ). Li et al confirmed that the corrosion resistance of Cr 3 C 2 -based coatings is the result of oxide formation, such as Cr 2 O 3 and Ni 2 O 3 , protecting the substrate (Ref 8 ).…”

Section: Introductionmentioning

confidence: 99%

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Corrosion Behavior and Galvanic Corrosion Resistance of WC and Cr3C2 Cermet Coatings in Madeira River Water

et al. 2021

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Thermally sprayed cermet coatings are adequate solutions to improve cavitation and wear resistance of hydraulic turbines made of stainless steel (SS), especially in rivers with a high sediment load, such as the Madeira River in Brazil. However, some cermets are easily dissolved in river water, leading to premature failure of the coating and costly maintenance. Moreover, galvanic corrosion induced by coupling the cermet to a SS can accelerate the coating dissolution. Therefore, the corrosion resistance of six cermets (WC-12Co, WC-10Ni, WC-10Co-4Cr, Cr 3 C 2 -25NiCr, Cr 3 C 2 -10NiCr and Cr 3 C 2 -10Ni) and the galvanic corrosion resistance of these materials coupled to CA6NM SS were evaluated in a solution that simulated Madeira River water. WC-12Co and WC-10Ni cermets exhibited the highest corrosion rates, 0.077 and 0.068 mm/ year, respectively, whereas the Cr content in the WC-10Co-4Cr (0.017 mm/year) and Cr 3 C 2 -based coatings (0.005 to 0.007 mm/year) led them to corrode at slower rates. Moreover, the WC-10Co-4Cr and Cr 3 C 2 -based cermets exhibited negligible galvanic corrosion current when coupled to the CA6NM SS, making them good options to coat hydraulic turbines. In contrast, WC-12Co and WC-10Ni coatings underwent a more severe galvanic corrosion process, which would drastically reduce the lifespan of these materials as hydraulic turbine coatings.Keywords corrosion resistance Á Cr 3 C 2 -based coatings Á galvanic corrosion Á power plant Á turbines Á WC-based coatings This article is an invited paper selected from abstracts submitted for the 2020 International Thermal Spray Conference, ITSC2020, that was to be held from June 10-12, 2020, in Vienna, Austria. The conference was canceled due to the coronavirus (COVID-19) pandemic. The paper has been expanded from the planned presentation.

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Section: Introductionmentioning

confidence: 63%

Section: Resultsmentioning

confidence: 97%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Corrosion Behavior and Galvanic Corrosion Resistance of WC and Cr3C2 Cermet Coatings in Madeira River Water

et al. 2021

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“…The metallic coating was select from technical characteristics and mechanical properties of materials resistant to hightemperatures (boiler operating temperatures between 550-800 °C). The choice of arc spraying process was due to the possibility of producing a coating on large surfaces and field operation, which is reflected in relatively low production costs compared to other similar deposition techniques 6,7,30 . This work also motivates evaluating alternatives alloys to be used for the thermoelectric boiler environment to optimize the cost-benefit ratio of applicable materials, since nickelbased alloys are relatively expensive 24 .…”

Section: Introductionmentioning

confidence: 99%

Characterization of Fly Ash and a Protective Coating for Brazilian Thermal Power Plant Boilers

et al. 2020

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Thermoelectric power plants that use mineral coal show high wear in heat exchanger due to the action of several damage mechanisms associated with the impact of hard particles from the residue of burnt coal, the ashes. The employment of coatings should be given into consideration particularly for critical components, which are subject to severe erosive conditions is one of the solutions. However, the choice of material will depend on several factors, including the properties of aggressive ashes. This paper aims to characterize ashes generated by a Brazilian coal-based power plant and a FeCrNbNi-based metallic coating obtained by the electric arc spraying process. No trace of sulfur content was found in fly ashes and it was defined that wear is mainly related to the impact and energy of hard particles are the leading causes of degradation in coal-fired boiler equipment. According to the assessment, applied coating showed (5 ± 2)% by volume of pores and cracks, with 1.6% of oxides after the spraying process and hardness 35% greater than ash particles. Preliminary results in field operation suggest that the material showed relatively low wear compared to the original substrate and showed great applicability in controlling material deterioration for this purpose.

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Effects of trace La addition on corrosion properties of oxygen‐free copper tube in a formic acid environment

Wang

et al. 2023

Materials & Corrosion

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Oxygen‐free copper (OFC) tubes are widely used in heat‐transfer units. Due to the thickness of the OFC tube wall becoming thinner and thinner, higher demands are put forward for its corrosion resistance properties. We investigated the effects of trace La addition on the corrosion properties of OFC tubes in a formic acid environment through experiments of vapor corrosion and electrochemical corrosion. Although a small number of La would exist on the grain boundaries of copper tubes, there was no apparent influence on the grain size of OFC tubes. In HCOOH vapor, La addition increased the compactness of corrosion product films, decreased the size of corrosion pits, and improved the corrosion properties of OFC tube. Furthermore, rare earth La purified copper matrix, decreased the cathode area of impurities and inhibited the cathode reaction. Electrochemical corrosion resistance properties of the OFC tube were improved by the addition of trace La.

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A Comprehensive Review of Corrosion Resistance of Thermally-Sprayed and Thermally-Diffused Protective Coatings on Steel Structures

Cited by 80 publications

References 159 publications

Corrosion Behavior and Galvanic Corrosion Resistance of WC and Cr3C2 Cermet Coatings in Madeira River Water

Corrosion Behavior and Galvanic Corrosion Resistance of WC and Cr3C2 Cermet Coatings in Madeira River Water

Characterization of Fly Ash and a Protective Coating for Brazilian Thermal Power Plant Boilers

Effects of trace La addition on corrosion properties of oxygen‐free copper tube in a formic acid environment

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