Sacrificial Thermally Sprayed Aluminium Coatings for Marine Environments: A Review
Source abstract
Abstract
One of the corrosion mitigation methods that is used for the protection of steel operating in seawater environments involves the application of sacrificial metallic coatings (such as aluminium, zinc, and their alloys). This paper reviews current knowledge about thermally-sprayed (TS) and cold-sprayed (CS) Al coatings for the corrosion protection of steel. It also summarises the key findings of the substantial amount of work that has been devoted to understanding mechanisms and the parameters that control the performance of TS Al coatings, such as the spraying method and its parameters like coating thickness and the application of sealer. The paper includes suggestions for areas of further research that could lead to the development of more resilient and longer-lasting coatings, based on the results from both laboratory and field tests that have been published in the literature. It also highlights the need for conducting simulated laboratory tests at conditions of intended service and the importance of long-term testing.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: High-Temperature Coating Behaviors · Corrosion Behavior and Inhibition · Materials Engineering and Processing
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
School of Metallurgy and Materials, University of Birmingham, Edgbaston, Birmingham B15 2TT, UK
National Structural Integrity Research Centre, Cambridge CB21 6AL, UK
TWI, Cambridge CB21 6AL, UK
School of Engineering, University of Leicester, University Road, Leicester LE1 7RH, UK
Funding
Engineering and Physical Sciences Research Council
References (98)
Show source-provided references
1. Koch, G., Varney, J., Thompson, N., Moghissi, O., Gould, M., and Payer, J. (2016). International measures of prevention, application, and economics of corrosion technologies study. NACE Int., 2–6.
2. López-Ortega, A., Bayón, R., and Arana, J.L. (2019). Evaluation of protective coatings for high-corrosivity category atmospheres in offshore applications. Materials, 12.10.3390/ma12081325 ↗
3. Det Norske Veritas (2016). Recommended Practice DNVGL-RP-0416 Corrosion Protection for Wind Turbines, DET NORSK VERITAS.
4. Giudice, C., and Canosa, G. (2017). Organic-inorganic hybrid coatings for corrosion protection of metallic surfaces. New Technologies in Protective Coatings, IntechOpen.10.5772/65573 ↗
5. Corrosion control for marine- and land-based infrastructure applications
6. Det Norske Veritas (2017). Recommended Practice DNVGL-RP-B401 Cathodic Protection Design, DET NORSK VERITAS.
7. Sealer coatings for thermal-sprayed aluminum in the offshore industry
8. Electrochemical impedance spectroscopy analysis of cold sprayed and arc sprayed aluminium coatings serviced in marine environment10.1179/1743294411Y.0000000036 ↗
9. Thermal arc spray overview10.1088/1757-899X/46/1/012028 ↗
10. Wire-arc sprayed nickel based coatings for hydrogen evolution reaction in alkaline solutions10.1016/S0360-3199(98)00101-3 ↗
11. Beyond traditional coatings: A review on thermal-sprayed functional and smart coatings10.1007/s11666-019-00857-1 ↗
12. A review on thermal spray coating processes
13. Davis, J.R. (2004). Introduction to thermal spray processing. Handbook of Thermal Spray Technology, ASM International.
14. Sabard, A., and Hussain, T. (2018). Bonding mechanisms in cold spray deposition of gas atomised and solution heat-treated Al 6061 powder by EBSD. arXiv.10.1007/s10853-019-03736-w ↗
15. Critical assessment 11: Structural repairs by cold spray10.1179/1743284714Y.0000000723 ↗
16. Champagne, V.K. (2007). The Cold Spray Materials Deposition Process: Fundamentals and Applications, Woodhead Publishing Limited.10.1201/9781439824122 ↗
17. Pathak, S., and Saha, G.C. (2017). Development of sustainable cold spray coatings and 3D additive manufacturing components for repair/manufacturing applications: A critical review. Coatings, 7.10.3390/coatings7080122 ↗
18. Comparison of aluminum coatings deposited by flame spray and by electric arc spray10.1016/j.surfcoat.2007.05.067 ↗
19. Gartland, P.O., and Eggen, T.G. (1990). Cathodic and anodic properties of thermally sprayed Al and Zn-based coatings in seawater Paper No. 367. Proceedings of the Corrosion 90, NACE International.
20. Bardal, E. (1973, January 10–14). The effect of surface preparation on the adhesion of arc and flame-sprayed aluminum and zinc coatings to mild steel. Proceedings of the 7th International Metal Spraying Conference, London, UK.
21. Lieberman, E.S., Clayton, C.R., and Herman, H. (1984). Thermally Sprayed Active Metal Coatings for Corrosion Protection in Marine Environments, Report.
22. (1993). American Welding Society Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminium and Zinc and their Alloys and Composites, AWS C2.18.
23. Effect of powder size on the long-term corrosion performance of pure aluminium coatings on mild steel by cold spraying10.1002/maco.201609199 ↗
24. Effects of thickness of Al thermal spray coating for STS 30410.1016/S1003-6326(08)60379-9 ↗
25. Performance and microstructure analysis of 99.5% aluminium coating by thermal arc spray technique10.1016/j.proeng.2013.12.221 ↗
26. Thomason, W.H., Olsen, S., Haugen, T., and Fischer, K. (April, January 28). Deterioration of thermal sprayed aluminum coatings on hot risers due to thermal cycling Paper No. 04021. Proceedings of the Corrosion 2004, New Orleans, LA, USA.
27. American Welding Society (Corrosion Testing of Flame-Sprayed Coated Steel—19 Year Report C2.14-74, 1974). Corrosion Testing of Flame-Sprayed Coated Steel—19 Year Report C2.14-74.
28. Paul, S., Lee, C.M., and Harvey, M.D.F. (2012). Improved coatings for extended design life of 22%Cr duplex stainless steel in marine environments. Proceedings of the Thermal Spray 2012: Proceedings from the International Thermal Spray Conference and Exposition, ASM International.10.31399/asm.cp.itsc2012p0544 ↗
29. Paul, S., Harvey, M.D.F., Ho, Q.Y., Yunus, K., and Fisher, A.C. (2015). Corrosion testing of thermally sprayed aluminum. Proceedings of the Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, ASM International.10.31399/asm.cp.itsc2015p0964 ↗
30. Quale, G., Årtun, L., Iannuzzi, M., and Johnsen, R. (2017). Cathodic protection by distributed sacrificial anodes—A new cost- effective solution to prevent corrosion of subsea structures Paper No. 8941. Proceedings of the Corrosion 2017, NACE International.
31. Study of corrosion behaviour of Arc sprayed aluminum coating on mild steel10.1007/s11666-012-9810-x ↗
32. Properties of TSA in natural seawater at ambient and elevated temperature10.1002/maco.201810385 ↗
33. Technical note: Corrosion of cathodically polarized thermally sprayed aluminum in subsea mud at high temperature
34. Use of thermally sprayed aluminium (TSA) coatings to protect offshore structures in submerged and splash zones10.1016/j.surfcoat.2019.04.048 ↗
35. Effect of seawater constituents on the performance of thermal spray aluminum in marine environments10.1002/maco.201810764 ↗
36. Pore blocking characteristics of corrosion products formed on Aluminium coating produced by arc thermal metal spray process in 3.5 wt.% NaCl solution10.1016/j.conbuildmat.2016.03.135 ↗
37. Electrochemical corrosion behaviors of aluminum-based marine coatings in the presence of Escherichia coli bacterial biofilm10.1016/j.matchemphys.2016.01.038 ↗
38. Corrosion performance of Al–Al2O3 cold sprayed coatings on mild carbon steel pipe under thermal insulation10.1016/j.cjche.2016.10.004 ↗
39. Corrosion performance of damaged thermally sprayed aluminiun in synthetic seawater at different temperatures
40. Yung, T.Y., Chen, T.C., Tsai, K.C., Lu, W.F., Huang, J.Y., and Liu, T.Y. (2019). Thermal spray coatings of Al, ZnAl and Inconel 625 alloys on SS304L for anti-saline corrosion. Coatings, 9.10.3390/coatings9010032 ↗
41. Ghali, E. (2010). Corrosion Resistance of Aluminium and Magnesium Alloys: Understadning, Performance and Testing, John Wiley & Sons.10.1002/9780470531778 ↗
42. Improve sensitization and corrosion resistance of an Al-Mg alloy by optimization of grain boundaries
43. Effect of Mg concentration on interfacial strength and corrosion fatigue behaviour of thermal-sprayed Al-Mg coating layers10.1016/j.engfailanal.2018.02.012 ↗
44. Adamiak, M., Czupr Nski, A., Kopy, A., Monica, Z., Olender, M., and Gwiazda, A. (2018). The properties of arc-sprayed aluminum coatings on armor-grade steel. Metals, 8.10.3390/met8020142 ↗
45. Investigation of Al-Al2O3 cold spray coating formation and properties10.1007/s11666-007-9086-8 ↗
46. Corrosion characteristics of cold gas spray coatings of reinforced aluminum deposited onto carbon steel10.1016/j.corsci.2016.10.019 ↗
47. Al/Al2O3 composite coating deposited by flame spraying for marine applications: Alumina skeleton enhances anti-corrosion and wear performances10.1007/s11666-014-0056-7 ↗
48. Jazi, H.S. (2012). Thermal sprayed coatings used against corrosion and corrosive wear. Advanced Spray Applications, IntechOpen.10.5772/1921 ↗
49. (NORSOK Standard M-501 Surface Preparation and Protective Coating, 2004). NORSOK Standard M-501 Surface Preparation and Protective Coating.
50. Evaluation of protective coatings for offshore applications. Corrosion and tribocorrosion behaviour in synthetic seawater10.1016/j.surfcoat.2018.06.089 ↗
51. Development of a superhydrophobic and bactericide organic topcoat to be applied on thermally sprayed aluminum coatings in offshore submerged components10.1016/j.porgcoat.2019.105376 ↗
52. Deposition of duplex Al2O3 /aluminum coatings on steel using a combined technique of arc spraying and plasma electrolytic oxidation10.1016/j.apsusc.2005.04.036 ↗
53. Corrosion, wear and tribocorrosion performance of a thermally sprayed aluminum coating modified by plasma electrolytic oxidation technique for offshore submerged components protection10.1016/j.corsci.2018.08.001 ↗
54. Effect of epoxy resin sealing on corrosion resistance of arc spraying aluminium coating using cathode electrophoresis method10.1088/2053-1591/aaa055 ↗
55. Sealing Treatment of Aluminium Coating on S235 Steel with Thermal Diffusion of Zinc10.1007/s11666-015-0277-4 ↗
56. An effective and novel pore sealing agent to enhance the corrosion resistance performance of Al coating in artificial ocean water10.1038/srep41935 ↗
57. Lee, H., Kumar, A., Mandal, S., Singh, J.K., Aslam, F., Alyousef, R., and Albduljabbar, H. (2020). Effect of sodium phosphate and calcium nitrate sealing treatment on microstructure and corrosion resistance of wire arc sprayed aluminum coatings. Coatings, 10.10.3390/coatings10010033 ↗
58. Study on corrosion resistance properties of hydrothermal sealed arc sprayed aluminium coating10.1179/174329409X409459 ↗
59. Sealing HVOF thermally sprayed WC-CoCr coatings by sol-gel methods10.1007/s11666-011-9638-9 ↗
60. Effect of glass powder sealings on the corrosion resistance of arc sprayed Al coating10.1088/2053-1591/ab1a14 ↗
61. Effects of laser remelting on surface-interface morphologies, bonding modes and corrosion performances of arc-sprayed Al coating10.1108/ACMM-11-2015-1591 ↗
62. Performance history of thermal-sprayed aluminum coatings in offshore service
63. Knudsen, O.Ø., Rogne, T., and Røssland, T. (2004). Rapid degradation of painted TSA Paper No. 04023. Proceedings of the Corrosion 2004, NACE International.
64. Failure of aluminium metal spray/organic duplex coating systems on structural steel10.1179/1743278213Y.0000000131 ↗
65. Thomason, W.H. (1985, January 6–9). Offshore corrosion protection with thermal-sprayed aluminum. Proceedings of the Offshore Technology Conference, Houston, TX, USA.10.4043/4971-MS ↗
66. Huang, G., Lou, X., Wang, H., Li, X., and Xing, L. (2017). Investigation on the cathodic protection effect of low pressure cold sprayed AlZn coating in seawater via numerical simulation. Coatings, 7.10.3390/coatings7070093 ↗
67. Ce, N., and Paul, S. (2016). Thermally Sprayed Aluminium Coatings for the Protection of Subsea Risers and Pipelines Carrying Hot Fluids. Coatings, 6.10.3390/coatings6040058 ↗
68. Ce, N., and Paul, S. (2017). The effect of temperature and local pH on calcareous deposit formation in damaged thermal spray aluminum (TSA) coatings and its implication on corrosion mitigation of offshore steel structures. Coatings, 7.10.3390/coatings7040052 ↗
69. Effects of temperature and magnesium ions on calcareous deposition10.5006/1.3584974 ↗
70. A Study of calcareous deposits on cathodically protected mild steel in artificial seawater10.3390/met5010439 ↗
71. Knudsen, O.Ø., Van Bokhorst, J., Clapp, G., and Duncan, G. (2014, January 9–13). Corrosion of cathodically polarized TSA in subsea mud at high temperature Paper No. 4196. Proceedings of the Corrosion 2004, San Antonio, TX, USA.10.5006/1485 ↗
72. Paul, S. (2017, January 26–30). Protection of deep sea steel structures using thermally sprayed aluminium Paper No. 9009. Proceedings of the Corrosion 2017, New Orleans, LA, USA.
73. Effect of variations in sea water upon the corrosion of aluminum10.5006/0010-9312-36.8.423 ↗
74. Paul, S. (2019, January 24–28). Behavior of damaged thermally sprayed aluminum (TSA) in aerated and dearated seawater Paper No. 12766. Proceedings of the Corrosion 2019, Nashville, TN, USA.
75. Galvanic corrosion: I. current flow and polarization characteristics of the aluminium-steel and zinc-steel couples in sodium chloride solution10.1149/1.2428559 ↗
76. Pitting corrosion of metals. A review of the critical factors10.1149/1.1838615 ↗
77. Pitting corrosion of aluminum
78. Chloride ion interactions with oxide-covered aluminum leading to pitting corrosion: A review10.1149/2.1011409jes ↗
79. Steel cathodic protection afforded by zinc, aluminium and zinc/aluminium alloy coatings in the atmosphere10.1016/j.surfcoat.2004.04.023 ↗
80. Rios, G. (2012). Effect of chlorides on the electrochemical behaviour of thermally sprayed aluminium protective coatings. [Ph.D. Thesis, University of Manchester].
81. Il Effects of SO42-, S2O 32- and HSO4- Ion additives on the pitting corrosion of pure aluminium in 1 M NaCl solution at 40–70 °C10.1007/s10008-004-0629-3 ↗
82. Effect of sulfate ions on corrosion inhibition of AA 7075 aluminum alloy in sodium chloride solutions10.5006/1.3294360 ↗
83. An 18-year exposure test of thermal-sprayed Zn, Al, and Zn-Al coatings in marine environment10.5006/1.3280677 ↗
84. Mansford, R.E. (1956). Sprayed aluminium and zinc in corrosive environments. Corros. Technol., 314–316.10.1108/eb019224 ↗
85. Zinc-aluminium sprayed coatings10.1080/00202967.1964.11869929 ↗
86. Painting of metal-sprayed structural steelwork: Report on the condition of specimens after 10 years’ exposure10.1179/000705974798321242 ↗
87. Twenty year field study of the performance of coatings in seawater
88. Bukowski, J., and Kumar, A. (1982). Coatings and Cathodic Protection of Piling on Seawater: Results of 10-Year Exposure at LaCosta Island, Fl, Constr. Eng. Lab, US Army. Tech. Rep. M-321.
89. Corrosion behaviour of arc sprayed Al–Zn–Si–RE coatings on mild steel in 3.5wt% NaCl solution10.1016/j.electacta.2013.09.156 ↗
90. Influence of Zn and Mg alloying on the corrosion resistance properties of Al coating applied by arc thermal spray process in simulated weather solution10.1007/s40195-018-0704-x ↗
91. Corrosion mechanism and kinetics of Al-Zn coating deposited by arc thermal spraying process in saline solution at prolong exposure periods
92. Tiong, D.K.-K., and Pit, H. Experiences on “thermal spray aluminium (TSA)” coating on offshore structures Conference paper No. 04022. Proceedings of the Corrosion 2004.
93. Use of thermally sprayed aluminium in the Norwegian Offshore Industry
94. Knudsen, O.Ø. (2010). Coating Systems for LONG lifetime: Thermally Sprayed Duplex Systems SINTEF Report A14189, SINTEF.
95. Mandeno, W.L. (2012, January 11–14). Thermal metal spray: Successes, failures and lessons learned. Proceedings of the Proceedings of Australasian Corrosion Association Corrosion & Prevention Conference, Melbourne, Australia.
96. Altered specifications for the protection of Norwegian steel bridges and offshore structures against corrosion10.1002/stco.200910015 ↗
97. TWI Ltd. (2020, January 07). CROWN Project Commended for Offshore Win Corrosion Work. Available online: https://www.twi-global.com/media-and-events/press-releases/2018-02-collaborative-crown-project-commended-for-offshore-wind-corrosion-work.
98. Matthiesen, H. (2020, January 07). Arkona Offshore Wind Project. Available online: Ttps://www.norwep.com/content/download/32957/239720/version/1/file/Mathiesen+2017-12-04_Norwegian+Offshore+Delegation_Arkona+Offshore+Wind+Project.pdf.