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Investigation of Corrosion Characteristics of Plasma-Sprayed Composite Coating on Bearing Steel Through Electrochemical and Salt Spray Test

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Abstract

This paper evaluates corrosion characteristics of a new material combination for a composite coating consisting of compounds Nickel Aluminum (NiAl), Aluminum oxide (Al2O3), and Cerium Oxide (CeO2). Composite coating NiAl + Al2O3 + CeO2 in the ratio of 70 + 10 + 20 is sprayed on EN31 through atmospheric plasma spray (APS) technique. Scanning electron microscopy/energy-dispersive analysis (SEM/EDAX), X-ray diffraction (XRD), and optical microscopy (OM) were used to characterize microstructure of the coating, porosity, and coating thickness. Potentiodynamic test followed by electrochemical impedance spectroscopy (EIS) data analysis and salt spray test were performed to evaluate corrosion characteristics. Area % porosity for NiAl + Al2O3 + CeO2 composite coating was found to be 1.34%. Coated EN31 shows 27% higher corrosion resistance compared to uncoated EN31 in Tafel plot and has a corrosion potential (Ecorr) of − 0.53 V which is 30% more when compared with uncoated EN31 under electrochemical test. Uncoated EN31 lost 5 times more weight than the coated EN31 under salt spray test conducted in a neutral mist of 5 wt% Sodium Chloride (NaCl) at 35 °C for 48 h. Under both the tests, results indicated that the composite coating NiAl + Al2O3 + CeO2 on EN31 exhibits better corrosion resistance on account of protective oxide layer formed on the surface when compared with the uncoated EN31.

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Data Availability

The datasets generated during the current study are available from the corresponding author on reasonable request.

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Authors and Affiliations

  1. VTU-RRC, Bangalore, 560078, Karnataka, India

    K Mohammed Ibrahim

  2. R.V. College of Engineering, Bangalore, 560059, Karnataka, India

    Sourabha S Havaldar

  3. Jain University, Bangalore, 560069, Karnataka, India

    Adarsha Hiriyannaiah

  4. Dayananda Sagar College of Engineering, Bangalore, 560078, Karnataka, India

    R. Keshavamurthy

Authors
  1. K Mohammed Ibrahim
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  2. Sourabha S Havaldar
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  3. Adarsha Hiriyannaiah
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  4. R. Keshavamurthy
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Contributions

Author MIK conducted experiments, analyzed, and interpreted experimental results and prepared draft manuscript. Author SSH designed and conceptualized experiments. Author AH contributed toward drafting manuscript. Author KR analyzed and interpreted experimental results. All authors reviewed the results and approved the final version of the manuscript.

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Correspondence to K Mohammed Ibrahim.

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Ibrahim, K.M., Havaldar, S.S., Hiriyannaiah, A. et al. Investigation of Corrosion Characteristics of Plasma-Sprayed Composite Coating on Bearing Steel Through Electrochemical and Salt Spray Test. J Bio Tribo Corros 8, 106 (2022). https://doi.org/10.1007/s40735-022-00706-9

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  • DOI: https://doi.org/10.1007/s40735-022-00706-9

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