Corrosion behaviour of AIP NiCoCrAlYSiB coating in salt spray tests

NiCoCrAlYSiB coatings were deposited by arc ion plating (AIP) and annealed/pre-oxidised under various conditions. The corrosion behaviour of as-deposited and annealed/pre-oxidised coatings was studied by salt spray testing in a neutral mist of 5 wt% NaCl at 35 °C for 200 h. The results showed that the as-deposited NiCoCrAlYSiB coating behaved poorly while the annealed and pre-oxidised ones performed much better in salt spray tests. The dense microstructure in annealed coatings and formation of α-Al₂O₃ scales on the surface during pre-oxidation improved the corrosion resistance in salt spray test. The corrosion process was investigated from the aspects of corrosion products, and its electrochemical mechanism was proposed as well.     

Slurry erosion–corrosion behaviour of high-velocity oxy-fuel (HVOF) sprayed Fe-based amorphous metallic coatings for marine pump in sand-containing NaCl solutions

Corrosion and slurry erosion–corrosion (E–C) behaviour of FeCrMoMnWBCSi amorphous metallic coatings (AMCs) compared with 304 stainless steel was investigated by static electrochemical measurements and weight loss tests under rotating conditions in simulated seawater. E–C rates of the AMCs increased with flow velocity, particle size, sand content and NaCl concentration. The AMCs are preferentially attacked at coating defects. The superior E–C resistance of AMCs can be attributed to the high micro-hardness, alloying elements and amorphous microstructure. The AMCs with better slurry E–C resistance may be good candidates to solve the E–C problems of marine pumps in sand-containing seawater.     

Corrosion properties of active screen plasma nitrided 316 austenitic stainless steel

AISI 316 austenitic stainless steel has been plasma nitrided using the active screen plasma nitriding (ASPN) technique. Corrosion properties of the untreated and AS plasma nitrided 316 steel have been evaluated using various techniques, including qualitative evaluation after etching in 50%HCl + 25%HNO₃ + 25%H₂O, weight loss measurement after immersion in 10% HCl, and anodic polarisation tests in 3.5% NaCl solution. The results showed that the untreated 316 stainless steel suffered severe localised pitting and crevice corrosion under the testing conditions. AS plasma nitriding at low temperature (420 °C) produced a single phase nitrided layer of nitrogen expanded austenite (S-phase), which considerably improved the corrosion properties of the 316 austenitic stainless steel. In contrast, AS plasma nitriding at a high temperature (500 °C) resulted in chromium nitride precipitation so that the bulk of the nitrided case had very poor corrosion resistance. However, a thin deposition layer on top of the nitrided case, which seems to be unique to AS plasma nitriding, could have alleviated the corrosion attack of the higher temperature nitrided 316 steel.     

Corrosion behaviour of low temperature plasma carburised 316L stainless steel in chloride containing solutions

The electrochemical corrosion behaviour of the carburised (expanded austenite) layer on 316L austenitic stainless steel produced by low temperature plasma carburising has been studied in 0.5 M NaCl and 0.5 M HCl + 0.5 M NaCl solutions. The present work focuses on the variation of the corrosion behaviour of the carburised layer with depth from the surface and the effect of carbon concentration on electrochemical behaviour. The results show that the carburised layer has excellent resistance to localised corrosion. There exists a critical carbon concentration, above which the expanded austenite possesses excellent resistance to both metastable pit formation and pit growth.     

Effect of iron-containing intermetallic particles on the corrosion behaviour of aluminium

The effect of heat treatment on the corrosion behaviour of binary Al-Fe alloys containing iron at levels between 0.04 and 0.42 wt.% was investigated by electrochemical measurements in both acidic and alkaline chloride solutions. Comparing solution heat-treated and quenched materials with samples that had been subsequently annealed to promote precipitation of Al₃Fe intermetallic particles, it was found that annealing increases both the cathodic and anodic reactivity. The increased cathodic reactivity is believed to be directly related to the increased available surface area of the iron-containing intermetallic particles acting as preferential sites for oxygen reduction and hydrogen evolution. These particles also act as pit initiation sites. Heat treatment also causes depletion in the solute content of the matrix, increasing its anodic reactivity. When breakdown occurs, crystallographic pits are formed with {1 0 0} facets, and are observed to contain numerous intermetallic particles. Fine facetted filaments also radiate out from the periphery of pits. The results demonstrate that the corrosion of aluminium is thus influenced by the presence of low levels of iron, which is one of the main impurities, and its electrochemical behaviour can be controlled by heat treatment.     

Corrosion behaviour of Terfenol-D

The corrosion behaviour of pseudo-binary compound Tb_0.3Dy_0.7Fe_1.92 (Terfenol-D) was studied in 3.5% NaCl and 0.01 N Na₂SO₄ solutions using Tafel polarisation, linear polarisation, electrochemical impedance spectroscopy and weight loss techniques. Electrochemical testing revealed the adverse effect of chloride ions, as corrosion rates were higher in 3.5% NaCl solutions than in 0.01 N Na₂SO₄ solutions. The effect of aeration was studied by conducting experiments in freely-aerated, deaerated and fully-aerated conditions. Absence of oxygen accelerated corrosion in chloride environment, due to increased hydrogen interaction in presence of destabilised surface films. The improved corrosion resistance in chloride-free environment was correlated with morphological features of the corroded surfaces. Micro-compositional analysis of the corrosion products revealed that the corrosion products were primarily rich in rare earth elements. A comparison of all experimental techniques showed that Tafel extrapolation and EIS techniques provided reliable estimates of corrosion rate.     

Corrosion behaviour of magnesium in ethylene glycol

Corrosion of magnesium engine components by coolant is an important issue in the automotive industry where magnesium alloys may be used. It is of significance to understand the corrosion behaviour of pure magnesium in ethylene glycol solutions, as this can provide a basis for developing new coolants for magnesium alloy engine blocks. In this paper, through corrosion and electrochemical tests, it was found that the corrosion rate of magnesium decreased with increasing concentration of ethylene glycol. Individual contaminants, such as NaCl, NaHCO₃, Na₂SO₄ and NaCl can make aqueous ethylene glycol solution more corrosive to magnesium. However, in NaCl contaminated ethylene glycol, NaHCO₃ and Na₂SO₄ showed some inhibition effect. The solution resistivity played an important role in the corrosion of magnesium in ethylene glycol solutions, and the competitive adsorption of ethylene glycol and the contaminants on the magnesium surface was also responsible for the observed corrosion behaviours. The corrosion of magnesium in ethylene glycol can be effectively inhibited by addition of fluorides that react with magnesium and form a protective film on the surface.     

Electrochemical response of AlNiLa amorphous and devitrified alloys

The electrochemical response of Al_94−xNi₆La_x alloys (x = 4, 5, 6, 7) after different stages of devitrification was studied in 0.05 M Na₂SO₄ as well as in different concentrations [0.001 M, 0.01 M and 0.1 M] NaCl solutions. Complementary crystallization studies were carried out to elucidate the composition dependent phase evolution in these alloys. It was observed that the primary crystallization did not cause any deterioration in the corrosion resistance of the alloys as compared to the amorphous alloys. In the case of Al₈₇Ni₆La₇, there was actually an improvement in the passivating ability in benign media. The various primary crystalline phases in the different alloys investigated did not cause different electrochemical responses. However, the onset of secondary crystallization caused a reduction in the corrosion resistance in the NaCl media through a loss in passivating ability of all the alloys. This is due to increased galvanic activity as well as the loss of the amorphous phase.     

Corrosion behaviour of magnetron sputtered α- and β-Ta coatings on AISI 4340 steel as a function of coating thickness

The corrosion behaviour of magnetron sputtered α- and β-Ta coated AISI 4340 steels was studied with potentiodynamic polarization and electrochemical impedance spectroscopy. The coating porosity was observed to decrease with increasing coating thickness. For coatings less than 10 μm thick (α- or β-Ta), porosity was significant and open pores resulted in severe localized corrosion of the steel substrate, coating delamination, and overall coating failure. Additionally, the β-Ta coatings were more susceptible than the α-phase to delamination. As for the 50 and 100 μm thick α-Ta coatings, the electrochemical impedance behaviour was comparable to that of Ta foil, demonstrating the coating viability and corrosion resistance.     

Corrosion behaviour of sintered NdFeB deposited with an aluminium coating

A protective, pure Al coating was deposited by direct current (DC) magnetron sputtering onto sintered NdFeB magnets. Separated, single phases of sintered NdFeB (the Nd-rich phase, the B-rich phase and the matrix phase) were prepared by arc melting for open circuit potential (OCP) tests. The corrosion process of the sintered NdFeB magnets coated with Al (Al/NdFeB) was studied experimentally. It was found that the corrosion process can be divided into three different stages. The Al coating cannot provide complete sacrificial protection for the sintered NdFeB magnets.     

Erosion–corrosion of HVOF-sprayed Fe-based amorphous metallic coating under impingement by a sand-containing NaCl solution

Erosion–corrosion (E–C) behaviour of a Fe-based amorphous metallic coating (AMC) compared with 304 stainless steel (304 s.s.) was studied under a slurry impingement condition in a sand-containing NaCl solution. AMC exhibited much higher resistance to E–C than 304 s.s. The weight loss reached the maximum at an impact angle of 90° and the critical flow velocity was about 15 m/s for AMC, while 45° and 9 m/s for 304 s.s. The increment in passive current density under impingement for AMC was about 10 times lower than 304 s.s. Passive films formed at different impact velocities were of different thicknesses.     

Corrosion behaviour of a magnesium matrix composite with a silicate plasma electrolytic oxidation coating

The corrosion behaviour of AZ92 magnesium alloy reinforced with various volume fractions of silicon carbide particles (SiCp) and treated by alternating current (AC) plasma electrolytic oxidation (PEO) was investigated in humid and saline environments. For untreated composites, corrosion attack started around the Al-Mn inclusions and gradually developed into general corrosion without significant galvanic coupling between the matrix and the SiCp. PEO coatings consisted mainly of MgO and Mg₂SiO₄, and revealed increased hardness, reduced thickness and slightly higher corrosion resistance with increasing proportion of reinforcement. Pit formation and hydration of the outer layer were the main mechanisms of corrosion of PEO-treated specimens.     

Electrochemical behaviour of Cu-40Zn in 3% NaCl solution polluted by sulphides: Effect of aminotriazole

The electrochemical behaviour of Cu-40Zn alloy, in 3% NaCl medium pure and polluted by 2 ppm of S²⁻ ions, has been studied in the absence and presence of the 3-amino-1,2,4 triazole (ATA) as corrosion inhibitor. Electrochemical measurements (polarisation curves and electrochemical impedance spectroscopy) showed that sulphides accelerate the alloy corrosion. The studies revealed that ATA inhibits both cathodic and anodic reactions, indicating a mixed type of inhibition. The inhibiting effect was higher in presence of S²⁻ ions than in its absence. Scanning electron microscopy analysis showed that the inhibitor acts by preventing the adsorption of S²⁻ ions, and formation of Cu₂S at the alloy surface. The inhibition efficiency reaches 98% at a concentration of 5 × 10⁻³ M.     

Corrosion behaviour of intermetallic aluminide coatings on nitrogen-containing austenitic stainless steels

The present work reports the effect of aluminide layers on the aqueous corrosion behaviour of four different 316L stainless steels containing various nitrogen contents (0.015%, 0.1%, 0.2% and 0.56% N). Diffusion annealed aluminide layers are generated over the surface by heat treatment of the aluminium precoated alloys at 750 °C for 25 h in nitrogen atmosphere. X-ray diffraction patterns of the surface modified samples showed the presence of AlN, Al₁₃Fe₄ and FeAl₂ phases. Diffusion of aluminum into the alloy, and the formation of AlN by the reaction of aluminium with matrix nitrogen, was identified using secondary ion mass spectrometry (SIMS). The nitrogen peak in the diffused layer was found to increase with increasing nitrogen content of the base alloy. SEM observation of cross-sectionally mounted alloys showed the presence of spherical AlN phase in addition to iron aluminide intermetallic phases. The role of such a composite surface layer containing intermetallic aluminides and nitride on the corrosion resistance of austenitic stainless steels in 0.5 M NaCl and 0.5 M sulphuric acid is discussed in greater detail based on open circuit potential (OCP)–time measurements, potentiodynamic polarisation studies and electrochemical impedance spectroscopy (EIS) investigations. The aluminide layered alloy with 0.1% N content showed better corrosion performance. The presence of nitrogen was found to have a positive effect in enhancing the hardness of the composite layer. Role of matrix nitrogen on the microstructure and microchemical distribution at the surface, and its role on corrosion resistance in acidic and chloride media are discussed in detail.     

Oxidation behaviour of metallic glass foams

In this study, the effects of porosity on the oxidation behaviour of bulk-metallic glasses were investigated. Porous Pd- and Fe-based bulk-metallic glass (BMG) foams and Metglas ribbons were studied. Oxidizing experiments were conducted at 70 °C, and around 80 °C below glass-transition temperatures, (T_gs). Scanning-electron microscopy/energy-dispersive spectroscopy (SEM/EDS) studies revealed little evidence of oxidation at 70 °C. Specimens exhibited greater oxidation at T_g - 80 °C. Oxides were copper-based for Pd-based foams, Fe-, Cr-, and Mo-based for Fe-based foams, and Co-based with borosilicates likely for the Metglas. Pd-based foams demonstrated the best oxidation resistance, followed by Metglas ribbons, followed by Fe-based foams.     

Electrochemical behavior of multicomponent amorphous and nanocrystalline Zr-based alloys in different environments

Electrochemical behavior of multicomponent melt spun Zr-based amorphous as well as nanocrystalline alloys have been studied in three different corrosive media (neutral NaCl, basic NaOH and acidic H₂SO₄ solutions). Due to the presence of strong passivating elements, (Zr and Ti) melt spun ternary alloys (Zr₅₅Ti₂₅Ni₂₀) have shown complete passivation in NaCl solution even as they contain a small amount of crystallinity. Amorphous multicomponent alloys containing Cu (Zr₅₈Cu₂₈Al₁₀Ti₄ and Zr₆₅Cu_7.5Al_7.5Ni₁₀Pd₁₀) show active nature in NaCl solution and this is strongly related to selective dissolution of base metal (Zr) and enrichment of Cu in the pit region. In NaOH and H₂SO₄ solutions, all the alloys have shown complete passivation irrespective of the alloy composition.     

Electrochemical behaviour of amorphous and nanoquasicrystalline Zr-Pd and Zr-Pt alloys in different environments

The corrosion behaviour of melt spun amorphous and nanoquasicrystalline Zr₇₀Pd₃₀ and Zr₈₀Pt₂₀ alloy ribbons has been investigated using potentiodynamic polarization study in NaCl, H₂SO₄ and NaOH solutions at different concentrations. The amorphous and nanoquasicrystalline alloys show better corrosion resistance than Zr in all the solutions studied. Both the alloys are susceptible to chloride attack and pitting has been observed. Complete passivation has been observed in H₂SO₄, while gradual break down of passivating layer occurs in NaOH. In general, nanoquasicrystalline state in both the alloys shows better corrosion resistance than amorphous state in all the solutions studied.     

Pitting corrosion of spray formed Al-Li-Mg alloys

The pitting corrosion behaviour of two new spray formed alloys, designated OX24 and OX27, has been compared with spray formed AA7034 and more corrosion resistant AA5083 by polarisation tests. The new alloys have been designed for use in the aerospace industry where good corrosion resistance and specific mechanical properties are required. OX24 and AA5083 had good corrosion resistance; OX27 pitted immediately showing poor corrosion resistance. However, both OX24 and OX27 show better corrosion resistance than AA7034. Scanning electron microscopy showed that corrosion was associated with intermetallic particles, except in OX24 where initiation appeared not to be associated with the Zr-rich intermetallics.     

Corrosion behaviour of zinc deposits obtained under pulse current electrodeposition: Effects of coumarin as additive

The corrosion behaviour of zinc deposits obtained under pulsed current electrodeposition from an acidic chloride bath in the presence and absence of coumarin has been investigated. The effects of pulse peak current density (J_p) on the morphology of zinc deposits were studied by scanning electron microscopy. An increase in J_p from 40 to 280 A dm⁻² yields deposits with a finer grain size. The refinement of the grain size was more considerable in the presence of coumarin (J_p = 280 A dm⁻²). The preferred orientation of zinc deposits was studied by X-ray diffraction. At J_p = 40 A dm⁻², the preferred orientation of zinc deposits was (1 0 3) and changed to (0 0 2) at J_p = 80 A dm⁻². An increase in J_p to 280 A dm⁻² did not change the preferred crystallographic orientations except for an increase in the peak intensity of the (0 0 2) plane. In the presence of coumarin, the preferred crystallographic orientations changed at J_p = 280 A dm⁻² from the (0 0 2) plane to the (1 0 3) plane. The corrosion behaviour was investigated in an aerated 3.5% NaCl solution; the anodic polarization and electrochemical impedance spectroscopy curves were performed. The corrosion resistance of zinc deposits was improved by increasing the pulse peak current density (J_p); whereas, the presence of coumarin did not improve the corrosion resistance.     

Corrosion fatigue crack growth behaviour of naval steels

Fatigue crack growth behaviour of two varieties of HSLA steels used in naval structural applications have been evaluated in air and 3.5% NaCl solution. In air both the HSLA steels showed similar resistance to fatigue crack growth. However, in 3.5% NaCl, the fatigue crack growth resistance of HSLA-80 steel was superior to that of HSLA-100. The apparent inferiority of HSLA-100 to corrosion fatigue crack growth resistance is attributed to rapid film formation and rupture, and occurrence of planar modes of failure. Effect of R-ratio on air fatigue and corrosion fatigue crack growth behaviour is rationalised by the concept of crack closure. Effect of cyclic frequency on corrosion fatigue behaviour is examined. It is noted that the mechanism of corrosion fatigue crack growth for the two HSLA steels changes with attendant change in the Paris slope. This leads to increase or decrease of crack growth rates, depending up on the ΔK range of interest.