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Corrosion Performance of Wire Arc Deposited Zinc Aluminum Pseudo Alloy and Zinc 15 Aluminum Alloy Coatings on Steel in Chloride Environment

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Abstract

This study investigated the corrosion performance of wire arc deposited zinc-aluminum pseudo alloy coating (Zn-Al pseudo alloy) with higher aluminum content and Zn-15Al alloy coating in the aggressive chloride environment. The performance of both coatings was assessed by employing morphological analysis, chemical composition and material characterization tests, and electrochemical studies. Micrographs of the as-deposited coatings revealed a denser and compact microstructure in the pseudo alloy coating compared to Zn-15Al coating. The electrochemical test results demonstrated that the pseudo alloy coating exhibited a four times lower corrosion rate and four times higher corrosion resistance compared to the Zn-15Al coating. Although, the formation of simonkolleite is noticed in the corrosion products of both the coatings, a more thin and compact corrosion product layer is observed in the pseudo alloy coating. The superior performance of Zn-Al pseudo alloy coating can be attributed to the presence of higher aluminum content and the existence of zinc-rich and aluminum-rich areas in the coating microstructure, where zinc offers sacrificial protection at the aluminum-rich region boundaries, in addition to the formation of stable corrosion products of zinc at zinc-rich areas, passivation of aluminum at the aluminum-rich areas, reduced the overall rate of corrosion in such coatings.

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Acknowledgments

This work was supported by the National Science Foundation under Grant No. CMMI-1750316. The findings and opinions expressed in this article are those of the authors only and do not necessarily reflect the views of the sponsors. In addition, the suppliers and point of contacts from Thermal Spray Depot (Washington, PA, USA) are gratefully acknowledged for providing materials and support.

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Authors and Affiliations

  1. Department of Civil, Construction and Environmental Engineering, North Dakota State University, Fargo, USA

    Ratna Divya Yasoda & Ying Huang

  2. Department of Coatings and Polymeric Materials, North Dakota State University, Fargo, USA

    Xiaoning Qi

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  1. Ratna Divya Yasoda
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Ratna: Data curation, Methodology, Formal analysis, Investigation, Writing - original draft, Writing - review & editing. Ying Huang: Project administration, Funding acquisition, Supervision, Writing - review & editing. Xiaoning Qi: Supervision, Writing - review & editing.

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Correspondence to Ying Huang.

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Yasoda, R.D., Huang, Y. & Qi, X. Corrosion Performance of Wire Arc Deposited Zinc Aluminum Pseudo Alloy and Zinc 15 Aluminum Alloy Coatings on Steel in Chloride Environment. J Therm Spray Tech 31, 1918–1933 (2022). https://doi.org/10.1007/s11666-022-01329-9

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