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Microstructure and Corrosion Behavior of Plasma-Sprayed Nanodiamond-Reinforced NiAl Nanocomposite Coating

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Abstract

Zero-dimensional structure, unique mechanical properties and potential thermal and chemical stability of nanodiamond (ND) make it a wise choice for reinforcement in metal matrix composites. Current study reveals the corrosion resistance (CR) of ND (0-1 wt.%)-reinforced Nickel-Aluminum (NiAl) coatings fabricated using atmospheric plasma spraying. The phase examination and microstructure demonstration of the powders and coatings were carried out using various characterization techniques, such as x-ray diffraction, Transmission Electron Microscopy, Scanning Electron Microscopy etc. Further, x-ray photoelectron spectroscopy reveals the retention of ~ 69% sp3 hybridized ND in the coating. The electrochemical tests in 3.5 wt.% NaCl solution reveals that 0.1 wt.% ND-reinforced NiAl coating demonstrated the best CR among all coatings, with a CR value of 0.16 mpy, which is ~ 5 times better than pristine NiAl coating. This improvement is ascribed to the minimization of defects in the coating after reinforcement and formation of stable passive film in the immersed situation. However, increasing the ND content masked its benefits and on contrary, resulted in increased CR due to predominantly acting micro-galvanic corrosion. Post corrosion characterizations approaches were made to validate the after corrosion results and have been discussed in details.

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Acknowledgments

Author of this paper, Kamlesh Kumar Mirche, and Anup Kumar Keshri acknowledge Indian Institute of Technology Patna for giving the infrastructure and financial support for this work.

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Authors and Affiliations

  1. Plasma Spray Coating Laboratory, Metallurgical and Materials Engineering, Indian Institute of Technology Patna, Patna, Bihar, 801106, India

    Kamlesh Kumar Mirche, Krishna Kant Pandey & Anup Kumar Keshri

  2. Department of Mechanical Engineering, National Institute of Technology Patna, Patna, Bihar, 800005, India

    Shailesh Mani Pandey

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  1. Kamlesh Kumar Mirche
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Mirche, K.K., Pandey, K.K., Pandey, S.M. et al. Microstructure and Corrosion Behavior of Plasma-Sprayed Nanodiamond-Reinforced NiAl Nanocomposite Coating. J Therm Spray Tech 32, 1299–1310 (2023). https://doi.org/10.1007/s11666-023-01558-6

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