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Enhanced corrosion and wear resistance of Zn–Ni/Cu–Al2O3 composite coating prepared by cold spray

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Abstract

In order to improve the cathodic protection and wear resistance of cold spraying Zn-based coatings, Zn–Ni/Cu–Al2O3 composite coating was prepared by co-depositing Zn powders, nickel-coated Cu powders, and Al2O3 powders on the steel substrate using the low-pressure cold spraying method. The structure and composition of Zn–Ni/Cu–Al2O3 coatings were analyzed by scanning electron microscopy, energy dispersive spectrum analysis, and X-ray diffraction, respectively. And their wear and corrosion resistance were tested. The results show that the structure of the Zn–Ni/Cu–Al2O3 composite coating is compact and the nickel powder is evenly distributed in the coating. Compared with the Zn–Al2O3 coating and Zn–Cu–Al2O3 coating, the Zn–Ni/Cu–Al2O3 composite coating has better wear resistance in air and stronger corrosion resistance in the 3.5 wt.% NaCl solutions. The Zn–Ni/Cu–Al2O3 coating has the lowest corrosion rate and maximum impedance after the immersion and scratch tests. Due to the promoting effect of Ni, the Zn–Ni/Cu–Al2O3 coating can quickly form a dense protective layer of corrosion products, which makes the Zn–Ni/Cu–Al2O3 composite coating has better cathodic protection and defect self-repair performance.

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Funding

This work was supported by the National Natural Science Foundation of China (No. 52105176 and No. 51709049), the National Key R&D Program of China (2021YFB3400601), and the Program for Guangdong Introducing Innovative and Entrepreneurial Teams (2019BT02Z393).

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Authors and Affiliations

  1. School of Materials and Energy, Guangdong University of Technology, Guangzhou, 510006, People’s Republic of China

    Yuwen Liu, Jiahao Tang, Liuyan Zhang, Geng zhe Shen, Zhiwei Gu & Xiaohua Jie

  2. State Key Laboratory of Precision Electronic Manufacturing Technology and Equipment, Guangdong University of Technology, Guangzhou, 510006, People’s Republic of China

    Guibin Tan

  3. State Key Laboratory of Tribology, Tsinghua University, Beijing, 100084, People’s Republic of China

    Zhiwei Gu

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  1. Yuwen Liu
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  2. Guibin Tan
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Correspondence to Guibin Tan or Liuyan Zhang.

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Liu, Y., Tan, G., Tang, J. et al. Enhanced corrosion and wear resistance of Zn–Ni/Cu–Al2O3 composite coating prepared by cold spray. J Solid State Electrochem 27, 439–453 (2023). https://doi.org/10.1007/s10008-022-05335-3

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