Thermal Sprayed Coatings Used Against Corrosion and Corrosive Wear

A mathematical model for failure prediction and reliability assessment of coating-substrate system is developed based on a multidisciplinary approach. Two models for diffusion and bending of bi-layer cantilever beam have been designed separately based on the concepts of material science and solid mechanics respectively. Then, these two models are integrated to design an equation for debonding driving force under mesomechanics concepts. Mesomechanics seeks to apply the concepts of solid mechanics to microstructural constituent of materials such as coatings. This research takes the concepts of mesomechanics to the next level in order to predict the performance and assess the reliability of coatings based on the measure of debonding driving force. The effects of two parameters i.e. interface roughness and coating thickness on debonding driving force have been analysed using finite difference method. Critical/ threshold value of debonding driving force is calculated which defines the point of failure of coating-substrate system and can be used for failure prediction and reliability assessment by defining three conditions of performance i.e. safe, critical and fail. Results reveal that debonding driving force decreases with an increase in interface roughness and coating thickness. However, this is subject to condition that the material properties of coating such as diffusivity should not increase and Young's modulus should not decrease with an increase in the interface roughness and coating thickness. The model is based on the observations recorded from experimentation. These experiments are performed to understand the behaviour of debonding driving force with the variation in interface roughness and coating thickness.

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“…Diffusivity and Young's modulus of coating depends on material's microstructure. [37,38] 2.3. Experimental observations…”

Section: Samples Preparation For Set-up 2-with Variable Coating Thickmentioning

confidence: 99%

Optimisation of interface roughness and coating thickness to maximise coating–substrate adhesion – a failure prediction and reliability assessment modelling

Nazir

Khan

Stokes

2015

Journal of Adhesion Science and Technology

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“…al. (2012), proved that, thermal insulation provided by Thermal Barrier Coatings (TBCs), improved component's creep and thermo-mechanical fatigue life, which thereby paved way for high-thrust gas turbine engines [30].…”

Section: Methods To Improve Corrossion Fatigue Lifementioning

confidence: 99%

Corrosion Fatigue of Welded Joints in Marine and Naval Structures, A Review

Kumar¹

2017

IJMPERD

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“…Sealer is often recommended for TSA to fill surface-connected porosities resulting from the spraying process and prevent the penetration of corrosive substance within the coating. It has been reported that TSA coatings perform better when sealed with organic or silicone sealers; however, one must note that this will increase the cost of the coating process [3][4][5]. Literature also mentions that inadequate sealing and inappropriate TSA thickness can result in blisters and failure of the coating under certain circumstances [3,6].…”

Section: Introductionmentioning

confidence: 99%

Thermally Sprayed Aluminum Coatings for the Protection of Subsea Risers and Pipelines Carrying Hot Fluids

Cé

Paul

2016

Coatings

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This paper reports the effect of boiling synthetic seawater on the performance of damaged Thermally Sprayed Aluminum (TSA) on carbon steel. Small defects (4% of the sample's geometric surface area) were drilled, exposing the steel, and the performance of the coating was analyzed for corrosion potential for different exposure times (2 h, 335 h, and 5000 h). The samples were monitored using linear polarization resistance (LPR) in order to obtain their corrosion rate. Scanning electron microscopy (SEM)/energy dispersive X-ray spectroscopy (EDX) and X-ray diffraction (XRD) were used for post-test characterization. The results showed that a protective layer of Mg(OH) 2 formed in the damaged area, which protected the underlying steel. Additionally, no coating detachment from the steel near the defect region was observed. The corrosion rate was found to be 0.010-0.015 mm/year after 5000 h in boiling synthetic seawater.

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Thermal Sprayed Coatings Used Against Corrosion and Corrosive Wear

Cited by 92 publications

References 79 publications

Optimisation of interface roughness and coating thickness to maximise coating–substrate adhesion – a failure prediction and reliability assessment modelling

Optimisation of interface roughness and coating thickness to maximise coating–substrate adhesion – a failure prediction and reliability assessment modelling

Corrosion Fatigue of Welded Joints in Marine and Naval Structures, A Review

Thermally Sprayed Aluminum Coatings for the Protection of Subsea Risers and Pipelines Carrying Hot Fluids

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