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Microstructure, smoothening effect, and local defects of alumina sol-gel coatings on ground steel

  • Original Paper: Industrial and technological applications of sol-gel and hybrid materials
  • Published:
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Abstract

Porous alumina films with thicknesses of a few microns were prepared via a dip-coating technique on steel P92. The coating is shown to protect the steel against massive corrosion, which is typical in the hot reactive environment of coal-fired power plants. To mimic real conditions ground steel plates were coated with a boehmite-sol. This leads to an overall smoothing of the formerly rough surface. In the following short annealing step the inner porous construction with worm-like particles consisting of nano-crystallites and amorphous alumina is formed. Due to the simultaneous diffusion of chromium and iron ions out of the bulk steel material into the porous alumina coating, a dense interface with satisfactory adhesion is formed. However, the film exhibits few local defects like cracks or dense alumina nodules caused by steep edges in the ground surface or agglomeration of boehmite-sol components, respectively. Cracks especially have to be avoided. This problem can be overcome so far by slight modifications in the sol preparation process and surface treatment of the substrates. Nevertheless, the results demonstrate the potential of sol-gel-based alumina coatings as a time-saving and cost-saving protection type for commercial steel P92.

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Acknowledgment

This work was initiated and financially supported by the European project “Production of Coatings for New Efficient and Clean Coal Power Plant Materials” (POEMA, FP7-NMP, 310436). The authors wish to thank Romeo Saliwan Neumann for his contributions to the SEM studies.

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Authors and Affiliations

  1. Federal Institute for Materials Research and Testing, Unter den Eichen 87, Berlin, 12205, Germany

    M. Nofz, I. Dörfel, R. Sojref, N. Wollschläger, M. Mosquera-Feijoo & A. Kranzmann

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  1. M. Nofz
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  2. I. Dörfel
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  3. R. Sojref
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  4. N. Wollschläger
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Correspondence to M. Nofz.

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Nofz, M., Dörfel, I., Sojref, R. et al. Microstructure, smoothening effect, and local defects of alumina sol-gel coatings on ground steel. J Sol-Gel Sci Technol 81, 185–194 (2017). https://doi.org/10.1007/s10971-016-4188-8

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  • DOI: https://doi.org/10.1007/s10971-016-4188-8

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