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Long-Term Corrosion Behavior of Flame Sprayed Al-Based Coatings After Nano-alumina Sealing Treatment

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Abstract

The effect of a nanoalumina sealant treatment on the long-term corrosion behavior of Al-based coatings deposited by flame spraying was investigated. X-ray diffraction and scanning electron microscopy were used to analyze the surface morphology and microstructure of the unsealed and sealed coatings. The long-term ability of the coatings to withstand corrosion was examined by electrochemical corrosion tests and salt spray corrosion experiments. The results indicate that loose pores and microcracks exist on the surface of the as-sprayed Al-based coatings. The morphologies of the surfaces of the sealed Al-based coatings are dense and flat. Electrochemical corrosion results show that the sealing treatment can effectively reduce the density of the corrosion current and improve the impedance values of all coatings. The sealing treatment prevents the corrosion medium from penetrating into the coating because defects such as pores and microcracks are filled with sealant, which can significantly improve the corrosion resistance of Al-based coatings. The corrosion current densities of the sealed coatings after salt spray corrosion tests are higher than those without salt spray corrosion experiments. With increasing salt spray corrosion time, the corrosion current densities of the sealed Al, Al-Mg and Al-Si coatings decrease, while the corrosion current density of the sealed Al-Cu coating rises gradually. The salt spray corrosion results indicate that sealed Al-based coatings are effective for preventing the long-term corrosion of components in marine environments.

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Acknowledgment

The financial supports of the National Key Research and Development Program of China (Grant No. 2018YFA0704604), the Natural Science Foundation of Jiangsu Province (Grant No. BK20200939), the China Postdoctoral Science Foundation (Grant No. 2020M671619), Yangzhou City and Yangzhou University Cooperation Foundation (Grant Nos. YZ2022182, YZ2021153), the Postdoctoral Science Foundation of Jiangsu Province (Grant No. 2020Z450), Jiangsu Key Laboratory of Green Process Equipment (Grant No. GPE202204) and Changzhou Sci & Tech Program (Grant No. CJ20220124) are gratefully acknowledged by the authors.

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Authors and Affiliations

  1. College of Mechanical Engineering, Yangzhou University, Yangzhou, 225127, China

    Xinlong Wei, Fanchang Dai, Aolin Ban & Chao Zhang

  2. Jiangsu Key Laboratory of Green Process Equipment, Changzhou University, Changzhou, 213164, China

    Xinlong Wei & Lin Liu

  3. School of Mechanical and Power Engineering, Nanjing Tech University, Nanjing, China

    Nian Li

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  1. Xinlong Wei
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Correspondence to Chao Zhang.

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Wei, X., Dai, F., Ban, A. et al. Long-Term Corrosion Behavior of Flame Sprayed Al-Based Coatings After Nano-alumina Sealing Treatment. J Therm Spray Tech 32, 2157–2169 (2023). https://doi.org/10.1007/s11666-023-01618-x

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