Corrosion-resistant metallic coatings for aluminum alloys by cold spray

Witharamage, C.S.; Alrizqi, Mohammed A.; Chirstudasjustus, Jijo; Darwish, Ahmed A; Ansell, Troy Y.; Nieto, Andy; Gupta, Rajeev

doi:10.1016/j.corsci.2022.110720

Cited by 30 publications

(10 citation statements)

References 72 publications

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“…In contrast to the thermal spray method [63] and beam (laser or electronic) deposition methods, in the CS, the particles remain in a solid state (at least for the vast majority of metallic materials) throughout the entire process [64]. Due to the application of low temperatures, the coating obtained by the CS method has unique properties [15,61,65,66]. The microstructure and properties of the original powders are preserved, which avoids the formation of oxides or any other unfavorable structural changes, which increases the durability and effectiveness of the coatings.…”

Section: Introductionmentioning

confidence: 99%

Cold-Sprayed Composite Metal-Fluoropolymer Coatings for Alloy Protection against Corrosion and Wear

et al. 2023

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Results of studying the properties of composite fluoropolymer-containing coatings formed by the cold spray (CS) method on the surface of constructional steel are presented. Different ways of protective coating formation are proposed. The composition of coatings was studied using SEM/EDX analysis. The incorporation of super-dispersed polytetrafluoroethylene (SPTFE) into the coating increases the corrosion resistance of the copper-zinc-based cold-sprayed coating. Analysis of the electrochemical properties obtained using EIS (electrochemical impedance spectroscopy) and PDP (potentiodynamic polarization) indicates that samples treated with SPTFE on a base copper-zinc coating showed lower corrosion current density and higher impedance modulus (jc = 8.5 × 10−7 A cm−2, |Z|f=0.1 Hz = 5.3 × 104 Ω∙cm2) than the specimen with cold-sprayed SPTFE (jc = 6.1 × 10−6 A cm−2, |Z|f=0.1 Hz = 8.1 × 103 Ω∙cm2). The best anticorrosion properties were revealed for the sample with a cold-sprayed base Cu-Zn layer annealed at 500 °C for 1 h, followed by SPTFE friction treatment and re-annealed at 350 °C for 1 h. The corrosion current density jc of such a coating is 25 times lower than that for the base Cu-Zn coating. The antifriction properties and hydrophobicity of the formed layers are described. Obtained results indicate that cold-sprayed polymer-containing coatings effectively improve the corrosion and wear resistivity of the treated material.

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Section: Introductionmentioning

confidence: 99%

Cold-Sprayed Composite Metal-Fluoropolymer Coatings for Alloy Protection against Corrosion and Wear

et al. 2023

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“…13,[16][17][18][27][28][29] In addition, the excellent dispersion capability of various elements in HEBM led to feedstock modification for additive manufacturing applications. [30][31][32] In recent years, the corrosion behavior of HEBM Al alloys has been studied. For example, Esquivel et al investigated the corrosion behavior of HEBM subsequently cold compacted binary Al-M (M-Cr, Mo, Ni, Ti, Mn, V, Nb) alloys.…”

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confidence: 99%

Effect of V Content on Corrosion Behavior of Al-V Alloys Produced by Mechanical Alloying and Subsequent Spark Plasma Sintering

Witharamage,

Christudasjustus,

Walunj

et al. 2024

J. Electrochem. Soc.

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Al-V alloys produced via high-energy ball milling have been reported to show simultaneous improvement of corrosion resistance and mechanical properties compared to traditional Al alloys. In these alloys, V content plays a crucial role in increasing or decreasing corrosion resistance. Therefore, the effect of V and microstructure on corrosion of high-energy ball milled and subsequently spark plasma sintered Al-xV alloys (x = 2, 5, 10 at.%) has been studied. Cyclic potentiodynamic polarization tests and electrochemical impedance spectroscopic analysis revealed that increments of V content up to 5 at. % enhanced the corrosion resistance of the alloy. However, highly heterogeneous microstructure in Al-10 at.%V resulted in significant localized corrosion over the immersion time. The electrochemical impedance spectroscopy studies over 14 days of immersion revealed underlying corrosion mechanisms.

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“…Since these alloys are in a metastable state due to high solid solubility of the alloying elements, they tend to decompose at high temperatures. Such an issue can be tackled, and the properties can be retained by adapting suitable manufacturing techniques, such as spark plasma sintering and cold spray, 5,[19][20][21][22] and selecting alloying elements with low diffusion coefficients in Al, such as V and Ti. [23][24][25] For instance, the age-hardening of NC-SS Al-5at%V alloy at 150 °C lowered the solid solubility of V in Al from 3.1 to 2.7 at%.…”

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confidence: 99%

Surface Film Formation on Al-V Alloys with Far-From-Equilibrium Microstructure

Christudasjustus

Witharamage

Vukkum

et al. 2023

J. Electrochem. Soc.

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Nanocrystalline supersaturated Al-V alloys produced by high-energy ball milling have been reported to exhibit enhanced corrosion resistance and mechanical properties compared to commercial Al alloys. Corrosion of passive alloys such as Al-V alloy relies on the characteristics of the surface film, which is studied using scanning/transmission electron microscopy and time-of-flight secondary ion mass spectrometry. The effect of microstructure and composition on the surface film has been investigated after different immersion periods (30 min, 2 hours, and 1 day) in 0.1 M NaCl. The surface film was complex and composed of oxidized Al and V. The heterogeneous surface film was observed due to the presence of secondary phases and initiation of localized corrosion. The void formation was observed beneath the surface film that would potentially cause pitting corrosion. The generation of nano-sized voids was dependent on grain orientation. Compared to pure Al, the chloride penetration is suppressed in Al-V alloys. The effect of composition and microstructure on surface film formation and attendant corrosion behavior is discussed herein.

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Corrosion-resistant metallic coatings for aluminum alloys by cold spray

Cited by 30 publications

References 72 publications

Cold-Sprayed Composite Metal-Fluoropolymer Coatings for Alloy Protection against Corrosion and Wear

Cold-Sprayed Composite Metal-Fluoropolymer Coatings for Alloy Protection against Corrosion and Wear

Effect of V Content on Corrosion Behavior of Al-V Alloys Produced by Mechanical Alloying and Subsequent Spark Plasma Sintering

Surface Film Formation on Al-V Alloys with Far-From-Equilibrium Microstructure

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