Corrosion Properties of S-Phase/Cr2N Composite Coatings Deposited on Austenitic Stainless Steel

In order to study the suitability of the S-phase layers as the interlayer for Cr₂N chromium nitride coatings, a number of composite coatings were deposited by the reactive magnetron sputtering (RMS) method on austenitic steel substrates with various initial surface conditions (as delivered and polished) and their corrosion resistance was assessed. Coatings with S-phase interlayer were deposited at three different nitrogen contents in the working atmosphere (15%, 30%, and 50%), which influenced the nitrogen concentration in the S-phase. Coatings with chromium, as a traditional interlayer to improve adhesion, and uncoated austenitic stainless steel were used as reference materials. Detailed microstructural and phase composition studies of the coatings were carried out by means of scanning electron microscopy (SEM), optical microscopy (LM), and X-ray diffraction (XRD) and were discussed in the context of results of corrosion tests carried out with the use of the potentiodynamic polarization method conducted in a 3% aqueous solution of sodium chloride (NaCl). The performed tests showed that the electrochemical potential of the S-phase/Cr₂N composite coatings is similar to that of Cr/Cr₂N coatings. It was also observed that the increase in the nitrogen content in the S-phase interlayer causes an increase in the polarization resistance of the S-phase/Cr₂N composite coating. Moreover, with a higher nitrogen content in the S-phase interlayer, the polarization resistance of the S-phase/Cr₂N coating is higher than for the Cr/Cr₂N reference coating. All the produced composite coatings showed better corrosion properties in relation to the uncoated austenitic stainless steel.     

Properties of Microplasma Coating on AZ91 Magnesium Alloy Prepared from Electrolyte with and without the Borax Addition

Magnesium alloys, due to their unique properties, low density and high strength properties, are becoming more frequently used in industrial applications. However, a limitation of their use may be the need to ensure high abrasive wear resistance and corrosion resistance. Therefore, magnesium alloys are often protected by applying protective coatings. The paper presents the influence of the modification of the electrolyte composition, with or without the addition of borax, on the morphology (observed by SEM method) and phase composition (analyzed by EDS and XRD) of the formed layers on the AZ91 magnesium alloy, and their abrasive wear (determined with Ball-on-Disc method) and corrosion resistance (evaluated using the immersion method and by electrochemical tests), especially in chloride solutions. It has been clearly demonstrated that the modification of the electrolyte composition significantly impacts the final properties of the protective coatings on the AZ91 alloy formed by the plasma electrolytic oxidation (PEO) process. On the basis of the results, it was found that the new type of PEO coatings with the borax addition, compared to base PEO coatings, showed significantly higher abrasion resistance and an order of magnitude lower corrosion rate.     

Corrosion Protective Film Formation on Mg Alloy AZ31 by Exposure to Dilute Selenite Solutions

The study of protective film formation on Mg alloys by exposure to sodium selenite solutions was conducted. Anodic polarization studies, electrochemical impedance spectroscopy studies, morphological analysis, and Energy-dispersive X-ray spectroscopy were performed on AZ31 Mg alloy after coating treatment in different concentrations of sodium selenite. The corrosion resistance was improved by around 5 times compared with control. Improved resistance to localized corrosion was observed in the coatings treated by 5 mM or 10 mM sodium selenite. The protection mechanism was ascribed to the transformation of selenite to insoluble selenium, the formation of insoluble MgSeO₃ hydrate, and polymerization of amorphous selenium.     

The Influence of Casein Coatings on the Corrosion Behavior of Mg-Based Alloys

This article discusses the influence of conversion casein coatings with a thickness of about 20 µm on the structure and the corrosion behavior of two magnesium alloys: MgCa2Zn1 and MgCa2Zn1Gd3. Casein is a protein that, along with whey protein, is a part of milk. Casein coatings are appropriate for bone growth because they contain high amounts of calcium and phosphorus. In this work, casein coatings and casein-free coatings were applied on Mg-based alloys using the conversion process. The structure and topography observations were presented. The corrosion behavior was determined by electrochemical and immersion tests, and electrochemical impedance spectroscopy (EIS) in chloride-rich Ringer solution. The obtained results show that conversion casein coatings effectively protect Mg-based alloys against corrosion. This was confirmed by higher corrosion potentials (E_corr), polarization resistances (R_p) derived from Tafel’s and EIS analysis, as well as low hydrogen release. The volume of hydrogen released after 216 h of immersion for casein coatings applied to MgCa2Zn1 and MgCa2Zn1Gd3 alloys was 19.25 and 12.42 mL/cm², respectively. The improvement in corrosion resistance of casein coatings was more significant for Mg alloy dopped with gadolinium. The lower corrosion rate of casein conversion coatings is explained by the synergistic effect of the addition of Gd in the Mg-based alloy and the formation of dense, tight conversion casein coatings on the surface of this alloy.     

Effect of Al Concentration on Microstructure and Properties of AlNbTiZr Medium-Entropy Alloy Coatings

The AlNbTiZr medium-entropy alloy (MEA) coatings with different Al contents were prepared on N36 zirconium alloy substrates by RF magnetron co-sputtering. The morphology, microstructure, mechanical properties, surface wettability and corrosion resistance of the AlNbTiZr MEA coatings were studied to evaluate the surface protection behavior of zirconium alloy cladding under operation conditions of a pressurized water reactor. The results showed that all the coatings were composite structures with amorphous and bcc-structured nanocrystals. With the increase of Al content, both the elastic modulus and hardness decreased first and then increased. The hydrophobicity of the coatings was enhanced compared with that of the substrate. The 10.2 at.% Al AlNbTiZr coating had the best corrosion resistance and the minimum oxygen penetration depth, which originated from the formation of a denser oxide layer consisting of Nb₂Zr₆O₁₇ and ZrO₂. This study provides an improved idea for the design and development of Al-containing MEA coating materials for accident tolerant fuel.     

The Effect of Electrophoretic Deposition Parameters on the Microstructure and Adhesion of Zein Coatings to Titanium Substrates

Zein coatings were obtained by electrophoretic deposition (EPD) on commercially pure titanium substrates in an as-received state and after various chemical treatments. The properties of the zein solution, zeta potential and conductivity, at varying pH values were investigated. It was found that the zein content and the ratio of water to ethanol of the solution used for EPD, as well as the process voltage value and time, significantly influence the morphology of coatings. The deposits obtained from the solution containing 150 g/L and 200 g/L of zein and 10 vol % of water and 90 vol % of ethanol, about 4–5 μm thick, were dense and homogeneous. The effect of chemical treatment of the Ti substrate surface prior to EPD on coating adhesion to the substrate was determined. The coatings showed the highest adhesion to the as-received and anodized substrates due to the presence of a thick TiO₂ layer on their surfaces and the presence of specific surface features. Coated titanium substrates showed slightly lower electrochemical corrosion resistance than the uncoated one in Ringer’s solution. The coatings showed a well-developed surface topography compared to the as-received substrate, and they demonstrated hydrophilic nature. The present results provide new insights for the further development of zein-based composite coatings for biomedical engineering applications.     

Effect of (NH4)2ZrF6, Voltage and Treating Time on Corrosion Resistance of Micro-Arc Oxidation Coatings Applied on ZK61M Magnesium Alloys

The effects of (NH₄)₂ZrF₆ concentration, voltage and treating time on the corrosion resistance of ZK61M magnesium alloy micro-arc oxidation coatings were studied by orthogonal experiments. The SEM result shows that the surface roughness and porosity of MAO coatings increased with (NH₄)₂ZrF₆ concentration, voltage and treating time as a whole, except the porosity decreased with treating time. EDS, XRD and XPS analysis show that (NH₄)₂ZrF₆ was successfully incorporated into coatings by reactive incorporation, coatings are dominantly composed of ZrO₂, MgO, MgF₂ and amorphous phase Mg phosphate. Potentiodynamic polarization was used to evaluate the corrosion property of coatings. When the concentration of (NH₄)₂ZrF₆ is 6 g/L, the voltage is 450 V, and the treating time is 15 min, the coating exhibits the best corrosion resistance which corrosion current density is four magnitudes lower than substrate attributed to the incorporation of ZrO₂ and the deposition of MgF₂ in the micropores.     

Effect of Mucin and Bicarbonate Ion on Corrosion Behavior of AZ31 Magnesium Alloy for Airway Stents

The biodegradable ability of magnesium alloys is an attractive feature for tracheal stents since they can be absorbed by the body through gradual degradation after healing of the airway structure, which can reduce the risk of inflammation caused by long-term implantation and prevent the repetitive surgery for removal of existing stent. In this study, the effects of bicarbonate ion (HCO₃⁻) and mucin in Gamble’s solution on the corrosion behavior of AZ31 magnesium alloy were investigated, using immersion and electrochemical tests to systematically identify the biodegradation kinetics of magnesium alloy under in vitro environment, mimicking the epithelial mucus surfaces in a trachea for development of biodegradable airway stents. Analysis of corrosion products after immersion test was performed using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX) and X-ray diffraction (XRD). Electrochemical impedance spectroscopy (EIS) was used to identify the effects of bicarbonate ions and mucin on the corrosion behavior of AZ31 magnesium alloys with the temporal change of corrosion resistance. The results show that the increase of the bicarbonate ions in Gamble’s solution accelerates the dissolution of AZ31 magnesium alloy, while the addition of mucin retards the corrosion. The experimental data in this work is intended to be used as foundational knowledge to predict the corrosion behavior of AZ31 magnesium alloy in the airway environment while providing degradation information for future in vivo studies.     

Wear and Corrosion Resistance of Plasma Electrolytic Oxidation Coatings on 6061 Al Alloy in Electrolytes with Aluminate and Phosphate

Phosphate and aluminate electrolytes were used to prepare plasma electrolytic oxidation (PEO) coatings on 6061 aluminum alloy. The surface and cross-section microstructure, element distribution, and phase composition of the PEO coatings were characterized by SEM, EDS, XPS, and XRD. The friction and wear properties were evaluated by pin-on-disk sliding tests under dry conditions. The corrosion resistance of PEO coatings was investigated by electrochemical corrosion and salt spray tests in acidic environments. It was found that the PEO coatings prepared from both phosphate and aluminate electrolytes were mainly composed of α-Al₂O₃ and γ-Al₂O₃. The results demonstrate that a bi-layer coating is formed in the phosphate electrolyte, and a single-layered dense alumina coating with a hardness of 1300 HV is realizable in the aluminate electrolyte. The aluminate PEO coating had a lower wear rate than the phosphate PEO coating. However, the phosphate PEO coating showed a better corrosion resistance in acidic environment, which is mainly attributed to the presence of an amorphous P element at the substrate/coating interface.     

Fluoride Treatment and In Vitro Corrosion Behavior of Mg-Nd-Y-Zn-Zr Alloys Type

Fluoride conversion coatings on Mg present many advantages, among which one can find the reduction of the corrosion rate under “in vivo” or “in vitro” conditions and the promotion of the calcium phosphate deposition. Moreover, the fluoride ions released from MgF₂ do not present cytotoxic effects and inhibit the biofilm formation, and thus these treated alloys are very suitable for cardiovascular stents and biodegradable orthopedic implants. In this paper, the biodegradation behavior of four new magnesium biodegradable alloys that have been developed in the laboratory conditions, before and after surface modifications by fluoride conversion (and sandblasting) coatings, are analyzed. We performed structural and surface analysis (XRD, SEM, contact angle) before and after applying different surface treatments. Furthermore, we studied the electrochemical behavior and biodegradation of all experimental samples after immersion test performed in NaCl solution. For a better evaluation, we also used LM and SEM for evaluation of the corroded samples after immersion test. The results showed an improved corrosion resistance for HF treated alloy in the NaCl solution. The chemical composition, uniformity, thickness and stability of the layers generated on the surface of the alloys significantly influence their corrosion behavior. Our study reveals that HF treatment is a beneficial way to improve the biofunctional properties required for the studied magnesium alloys to be used as biomaterials for manufacturing the orthopedic implants.     

Potentiodynamic Polarization Studies and Surface Chemical Composition of Bismuth Titanate (BixTiyOz) Films Produced through Radiofrequency Magnetron Sputtering

The applications of Bismuth Titanate (Bi_xTi_yO_z) materials have been focused on their electronic and optical properties, but with respect to the use of these compounds in applications like corrosion resistance, have been very few or nonexistent. For this reason, in the present investigation Bi_xTi_yO_z thin films were deposited using RF magnetron sputtering onto silicon wafers, stainless steel 316L, and titanium alloy (Ti₆Al₄V) substrates, in order to carry out a study of the corrosion behavior of this compound. The structural properties of the coatings were studied through X-ray diffraction (XRD), the morphology was determined using Scanning Electron Microscopy (SEM), the corrosion resistance behavior of the coated and uncoated substrates was evaluated via the Potentiodynamic Polarization technique, and surface chemical composition was evaluated through X-ray photoelectron spectroscopy (XPS). The XRD results indicated that the films were amorphous. The SEM micrographs showed that the deposited films were homogeneous, but in some cases there were cracks. The potentiodynamic polarization technique showed that the corrosion current in the coated substrates decreased by an order of two magnitudes with respect to the uncoated substrates, but in both cases the corrosion mechanism was pitting due to the pores in the film. The XPS analysis shows that the deposited films contain both Bi³⁺ and Ti⁴⁺.     

Effect of SiC Nanoparticles on AZ31 Magnesium Alloy

Magnesium alloys are attractive for the production of lightweight parts in modern automobile and aerospace industries due to their advanced properties. Their mechanical properties are usually enhanced by the incorporation with reinforcement particles. In the current study, reinforced AZ31 magnesium alloy was fabricated through the addition of bulk Al and the incorporation of SiC nanoparticles using a stir casting process to obtain AZ31-SiC nanocomposites. Scanning electron microscope (SEM) investigations revealed the formation of Mg₁₇Al₁₂ lamellar intermetallic structures and SiC clusters in the nanocomposites. Energy dispersive spectroscopy (EDS) detected the uniform distribution of SiC nanoparticles in the AZ31-SiC nanocomposites. Enhancements in hardness and yield strength (YS) were detected in the fabricated nanocomposites. This behavior was referred to a joint strengthening mechanisms which showed matrix-reinforcement coefficient of thermal expansion (CTE) and elastic modulus mismatches, Orowan strengthening, and load transfer mechanism. The mechanical properties and wear resistance were gradually increased with an increase in SiC content in the nanocomposite. The maximum values were obtained from nanocomposites containing 1 wt% of SiC (AZ31-1SiC). AZ31-1SiC nanocomposite YS and hardness were improved by 27% and 30%, respectively, compared to AZ31 alloy. This nanocomposite also exhibited the highest wear resistance; its wear mass loss and depth of the worn surface decreased by 26% and 15%, respectively, compared to AZ31 alloy.     

Electrophoretic Deposition of Chitosan/h-BN and Chitosan/h-BN/TiO2 Composite Coatings on Stainless Steel (316L) Substrates

This article presents the results of an experimental investigation designed to deposit chitosan/hexagonal boron nitride (h-BN) and chitosan/h-BN/titania (TiO₂) composites on SS316L substrates using electrophoretic deposition (EPD) for potential antibacterial applications. The influence of EPD parameters (voltage and deposition time) and relative concentrations of chitosan, h-BN and TiO₂ in suspension on deposition yield was studied. The composition and structure of deposited coatings were investigated by FTIR, XRD and SEM. It was observed that h-BN and TiO₂ particles were dispersed in the chitosan matrix through simultaneous deposition. The adhesion between the electrophoretic coatings and the stainless steel substrates was tested by using tape test technique, and the results showed that the adhesion strength corresponded to 3B and 4B classes. Corrosion resistance was evaluated by electrochemical polarization curves, indicating enhanced corrosion resistance of the chitosan/h-BN/TiO₂ and chitosan/h-BN coatings compared to the bare stainless steel substrate. In order to investigate the in-vitro inorganic bioactivity, coatings were immersed in simulated body fluid (SBF) for 28 days. FTIR and XRD results showed no formation of hydroxyapatite on the surface of chitosan/h-BN/TiO₂ and chitosan/h-BN coatings, which are therefore non bioactive but potentially useful as antibacterial coatings.     

Performance of Sprayed PVDF-Al2O3 Composite Coating for Industrial and Civil Applications

Because of their great water repellency, Superhydrophobic coatings have a major impact on a variety of industrial applications. The current study’s key originality is the development of low-cost, stable, superhydrophobic, and corrosion-resistant composite coatings. In the present work, polyvinylidene fluoride (PVDF)/Al₂O₃ composite coatings were produced using the spray technique to investigate the wettability and corrosion behavior of the coated materials for industrial and civil applications. PVDF was mixed with various concentrations of Al₂O₃ nanoparticles, and the mixture was sprayed onto steel, aluminum, and glass substrates. The wettability and morphology of the coated surfaces were investigated using the sessile droplet method and scanning electron microscopy, respectively. The corrosion resistance of bare substrates was compared to that of those coated with PVDF alone and those coated with PVDF/Al₂O₃ nanoparticles using Tafel polarization techniques. The force of adhesion between the coat and the substrates was measured in pounds per square inch. A nanoindentation test was also used to measure the hardness of the coating layer. The PVDF/Al₂O₃ coated steel showed a significantly higher water contact angle and lower contact angle hysteresis, reaching 157 ± 2° and 7 ± 1°, respectively, compared to the coated aluminum and glass substrates. Corrosion test results showed that the superhydrophobic PVDF/Al₂O₃ coatings had a much higher corrosion protection efficiency for steel and aluminum than that of the PVDF ones. The PVDF/Al₂O₃ coated substrates showed moderate but still acceptable adhesion between the coating layer and the substrates. Moreover, the PVDF/Al₂O₃ coatings had much better mechanical properties than the PVDF only coatings. Such type of coating could be a promising candidate for possible industrial and civil applications.     

Preparation and Characterization of Hydroxyapatite Coating on AZ31 Magnesium Alloy Induced by Carboxymethyl Cellulose-Dopamine

Magnesium and its alloys have become potential implant materials in the future because of light weight, mechanical properties similar to natural bone, good biocompatibility, and degradability in physiological environment. However, due to the rapid corrosion and degradation of magnesium alloys in vivo, especially in the environment containing chloride ions, the application of magnesium alloys as implant materials has been limited. Therefore, improving the corrosion resistance of magnesium alloy and ensuring good biocompatibility is the main focus of the current research. In this study, hydroxyapatite coating was prepared on magnesium alloy surface using carboxymethyl cellulose-dopamine hydrogel as inducer to improve corrosion resistance and biocompatibility. Surface characterization techniques (scanning electron microscopy, Fourier-transformed infrared spectroscopy, energy dispersive X-ray spectroscopy- and X-ray diffraction) confirmed the formation of hydroxyapatite on the surface of AZ31 alloy. Corrosion resistance tests have proved the protective effect of Carboxymethyl cellulose-Dopamine/hydroxyapatite (CMC-DA/HA) coating on the surface of AZ31 alloy. According to MC3T3-E1 cell viability and Live/Dead staining, the coating also showed good biocompatibility. The results will provide new ideas for the biological application of magnesium alloys.     

A Comparative Study of Aluminium and Titanium Warm Sprayed Coatings on AZ91E Magnesium Alloy

Aluminium (Al) and titanium (Ti) coatings were applied on AZ91E magnesium alloy using a low-pressure warm spray (WS) method. The deposition was completed using three different nitrogen flow rates (NFR) for both coatings. NFR effects on coating microstructure and other physical properties were systematically studied. Microstructural characterization was performed using scanning electron microscopy (SEM), and the porosity was estimated using two methods—image analysis and X-ray microtomography. The coating adhesion strength, wear resistance, and hardness were examined. The protective properties of the coatings were verified via a salt spray test. Decreasing NFR during coating deposition produced more dense and compact coatings. However, these conditions increased the oxidation of the powder. Al coatings showed lower hardness and wear resistance than Ti coatings, although they are more suitable for corrosion protection due to their low porosity and high compactness.     

Nano-TiO2 Coating Layers with Improved Anticorrosive Properties by Aerosol Flame Synthesis and Thermophoretic Deposition on Aluminium Surfaces

TiO₂ in the form of nanoparticles is characterized by high photocatalytic activity and high resistance to oxidation, making it an excellent candidate to realize coatings for improving the corrosion resistance of aluminium surfaces. Different coating technologies have been proposed over the years, which often involve the use of toxic compounds and very high temperatures. In this work, an alternative and novel one-step method for the coating of aluminium alloy surfaces with titania nanoparticles is presented. The method is based on the combination of aerosol flame synthesis and direct thermophoretic deposition and allows to produce nanostructured thin coating layers of titania with different features. Specifically, 3.5 nm anatase nanoparticles were synthesized and deposited onto aluminium alloy AA2024 samples. The thickness of the coating was changed by modifying the total deposition time. A thermal annealing treatment was developed to improve the adhesion of nano-titania on the substrates, and the morphology and structures of the coatings were characterized using (ultra violet) UV-vis absorption, scanning electron microscopy, transmission electron microscopy and Raman spectroscopy. The corrosion resistance behavior of the coatings was evaluated by means of electrochemical polarization measurements, coupled with a numerical analysis using COMSOL software. Both the experimental and numerical electrochemical polarization curves showed a significant increase in the corrosion potential of coated substrates with respect to the bare aluminium and a decrease in the current density. The coatings obtained with higher deposition time and greater thickness showed the best performances in terms of the resistance of the aluminium surfaces to corrosion.     

Effects of Inorganic Metabolites of Sulphate-Reducing Bacteria on the Corrosion of AZ31B and AZ63B Magnesium Alloy in 3.5 wt.% NaCl Solution

This study seeks prevent and alleviate the failure of magnesium alloy anodes in pipelines, which we suspect is a problem related to SRB. The electrochemical corrosion behaviour of two kinds of magnesium alloys, AZ31B and AZ63B, in 3.5 wt.% NaCl solution with sulphide or phosphide—the two main inorganic metabolites of sulphate-reducing bacteria—were studied by electrochemical tests combined with other characterisation methods such as scanning electron microscopy and X-ray diffraction. The results show that the corrosion film formed by inorganic metabolites of SRB’s initial stage of corrosion (1–3 d) can lead to the corrosion of magnesium alloys. However, the loose and porous corrosion product film cannot protect the substrate effectively. The inorganic metabolites in the solution can accelerate the corrosion of the surface of magnesium alloy after the corrosion products have fallen off. This study provides a theoretical basis for alleviating the premature failure of magnesium alloy anodes and for corrosion protection in the future.     

Stability of Octadecyltrimethoxysilane-Based Coatings on Aluminum Alloy Surface

Long-term stability in contact with water of organosilane layers formed by octadecyltrimethoxysilane (ODTMS) on polished aluminum alloy (AA2024) through dip-coating was studied by combining SEM, water contact angle measurements, and X-ray photoelectron spectroscopy. Similar organosilane layers were formed on AA2024 coated with permanganate conversion coating, 1,2-bis(triethoxysilyl)ethane (BTSE) and hydrated SiO_x as under-layers, after which their long-term durability was also tested. During immersion in water for about one month, all the samples exhibited a decrease in hydrophobicity, implying the prepared organosilane layer was not stable over time, gradually hydrolyzing and letting water interact with the underlying layer. In parallel, SEM images of one-layer samples taken after immersion showed clear signs of local electrochemical corrosion, while XPS analysis confirmed a loss of silicon from the surface layer. The highest stability over time was demonstrated by a one-layer sample prepared in an ethanol/water bath for 5 min and by a similar ODTMS layer prepared on hydrated MnO_x as an under-layer.     

Study of the Microstructure and Corrosion Properties of a Ni-Based Alloy Coating Deposited onto the Surface of Ductile Cast Iron Using High-Speed Laser Cladding

To improve the surface corrosion resistance of ductile iron, Ni-based alloy coatings were prepared using a high-speed laser cladding technology with different levels of laser power. The microstructure, phases, and corrosion properties of the coatings were investigated by scanning electron microscopy (SEM), X-ray diffraction (XRD), and an electrochemical workstation. Variations in laser power did not change the main phases of the coatings, which were composed of γ-Ni, Ni₃B, Ni₂Si, and Cr₂₃C₆. With an increase in power, the degree of segregation in the coating decreased, sufficient melting between elements was achieved, and the chemical composition became more uniform. Enhancement of the laser power resulted in more energy being injected into the cladding, which allowed adequate growth of tissue, and dendrites continued to grow in size as the power increased. The self-corrosion potentials of the coatings at laser power levels of 1.6, 2.0, and 2.4 kW were −625.7, −526.5, and −335.7 mV, respectively. The corrosion potential of the 2.4 kW coating was the highest, and the corroded surface of the cladding layer included mainly sizeable continuous structures with a light degree of corrosion and the highest corrosion resistance.