Wear and Corrosion Behavior of Zn-Ni-Cu and Zn-Ni-Cu-TiB2-Coated Mild Steel
Source abstract
Abstract
In this study, Zn-Ni-Cu and Zn-Ni-Cu-TiB2 were coated using a thermal spray (HVOF) process on a mild steel specimen. The coated specimens were characterized using Scanning Electron Microscope, Energy-Dispersive Spectroscopy, and x-ray-elemental mapping for surface morphology and coated powder distribution on the surface. The coated/uncoated mild steel specimens were tested for wear resistance using the pin-on-disc (ASTM G99-17) method. The wear volume loss of both coated Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on mild steel was less as compared to uncoated mild steel. For understanding the adhesion strength of the coating with the substrate, the coated samples of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on mild steel were subjected to the scratch test. For Zn-Ni-Cu and Zn-Ni-Cu TiB2-coated mild steel the adhesion strength was higher as compared to uncoated mild steel inferring a strong bond between coating and substrate and least delamination. Hardness induced due to coating was tested using the Vickers hardness test and significant improvement in hardness was observed in coated samples of Zn-Ni-Cu and Zn-Ni-Cu-TiB2-coated mild steel compared to uncoated mild steel. For corrosion resistance of coatings in an acidic medium, a 0.5 M HCl immersion cycle test was performed using ASTM G1-03, and ASTM G-31, standards for 28 days (672 h). The weight loss for uncoated mild steel was much higher as compared to Zn-Ni-Cu and Zn-Ni-Cu-TiB2-coated mild steel. XRD analysis also confirmed the least forms of rust on the surface of coated samples compared to uncoated mild steel post immersion cycle test. EIS/Tafel analysis in 0.5 M HCl also revealed that both Zn-Ni-Cu and Zn-Ni-Cu-TiB2 on mild steel were anti-corrosive as higher corrosion potential and lower corrosion current density were observed compared to uncoated mild steel. The results in every test were quite motivating and proved that these coatings were both wear and corrosion-resistant.
Source: expertdata · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: High-Temperature Coating Behaviors · Metal and Thin Film Mechanics · Metal Alloys Wear and Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (31)
Show source-provided references
1. S. Rashmi, L. Elias, and A.C. Hegde, Multilayered Zn-Ni Alloy Coatings for Better Corrosion Protection of Mild Steel, Eng. Sci. Technol. Int. J., 2017, 20(3), p 1227–1232.
2. M.R.Z. Meymian, A. Ghaffarinejad, R. Fazli, and A.K. Mehr, Fabrication and Characterization of Bimetallic Nickel-Molybdenum Nano-Coatings for Mild Steel Corrosion Protection in 3.5% NaCl Solution, Colloids Surf. A Physicochem. Eng. Asp., 2020, 593, p 124617.10.1016/j.colsurfa.2020.124617 ↗
3. S. Anwar, Y. Zhang, and F. Khan, Electrochemical Behaviour and Analysis of Zn and Zn-Ni Alloy Anti-corrosive Coatings Deposited from Citrate Baths, RSC Adv., 2018, 8(51), p 28861–28873.10.1039/C8RA04650F ↗
4. B. Lotfi, Elevated Temperature Oxidation Behavior of HVOF Sprayed TiB2 Cermet Coating, Trans. Nonferrous Met. Soc. China, 2010, 20(2), p 243–247.10.1016/S1003-6326(09)60129-1 ↗
5. M.M. Stack and T.M. Abd El-Badia, Some Comments on Mapping the Combined Effects of Slurry Concentration, Impact Velocity and Electrochemical Potential on the Erosion–Corrosion of WC/Co-Cr Coatings, Wear, 2008, 264(9–10), p 826–837.10.1016/j.wear.2007.02.025 ↗
6. M.A. Uusitalo, P.M.J. Vuoristo, and T.A. Mäntylä, Elevated Temperature Erosion–Corrosion of Thermal Sprayed Coatings in Chlorine Containing Environments, Wear, 2002, 252(7–8), p 586–594.10.1016/S0043-1648(02)00014-5 ↗
7. T. Zhang, K. Feng, Z. Li, and H. Kokawa, Effects of Rare Earth Elements on the Microstructure and Wear Properties of TiB2 Reinforced Aluminum Matrix Composite Coatings: Experiments and First Principles Calculations, Appl. Surf. Sci., 2020, 530, p 147051.10.1016/j.apsusc.2020.147051 ↗
8. P. Das, S. Paul, and P.P. Bandyopadhyay, HVOF Sprayed Diamond Reinforced Nano-structured Bronze Coatings, J. Alloy. Compd., 2018, 746, p 361–369.10.1016/j.jallcom.2018.02.307 ↗
9. N. Panich and Y. Sun, Mechanical Properties of TiB2-Based Nanostructured Coatings. Surf. Coat. Technol., 2005, 198(1–3), p 14–19.10.1016/j.surfcoat.2004.10.096 ↗
10. M. Federici, C. Menapace, A. Moscatelli, S. Gialanella, and G. Straffelini, Pin-On-Disc Study of a Friction Material Dry Sliding against HVOF Coated Discs at Room Temperature and 300 °C, Tribol. Int., 2017, 115, p 89–99.10.1016/j.triboint.2017.05.030 ↗
11. G. Bolelli, L.M. Berger, T. Börner, H. Koivuluoto, L. Lusvarghi, C. Lyphout, N. Markocsan, V. Matikainen, P. Nylén, P. Sassatelli, and R. Trache, Tribology of HVOF-and HVAF-Sprayed WC–10Co4Cr Hardmetal Coatings: A Comparative Assessment, Surf. Coat. Technol., 2015, 265, p 125–144.10.1016/j.surfcoat.2015.01.048 ↗
12. P. Mahato, G. Nyati, R.J. Singh, and S.K. Mishra, Nanocomposite TiSiBC Hard Coatings with High Resistance to Wear, Fracture and Scratching, J. Mater. Eng. Perform., 2016, 25(9), p 3774–3782.10.1007/s11665-016-2239-5 ↗
13. J. Meng, X. Shi, S. Zhang, M. Wang, F. Xue, B. Liu, W. Cui, and L. Bian, Friction and Wear Properties of TiN-TiB2-Ni Based Composite Coatings by Argon Arc Cladding Technology, Surf. Coat. Technol., 2019, 374, p 437–447.10.1016/j.surfcoat.2019.06.015 ↗
14. M. Mikula, B. Grančič, V. Buršíková, A. Csuba, M. Držík, Š Kavecký, A. Plecenik, and P. Kúš, Mechanical Properties of Superhard TiB2 Coatings Prepared by DC Magnetron Sputtering, Vacuum, 2007, 82(2), p 278–281.10.1016/j.vacuum.2007.07.036 ↗
15. V.A.D. Souza and A. Neville, Corrosion and Synergy in a WCCoCr HVOF Thermal Spray Coating—Understanding their Role in Erosion–Corrosion Degradation, Wear, 2005, 259(1–6), p 171–180.10.1016/j.wear.2004.12.003 ↗
16. S.B. Mishra, K. Chandra, and S. Prakash, Erosion–Corrosion Performance of NiCrAlY Coating Produced by Plasma Spray Process in a Coal-Fired Thermal Power Plant, Surf. Coat. Technol., 2013, 216, p 23–34.10.1016/j.surfcoat.2012.09.044 ↗
17. M.A. Zavareh, A.A.D.M. Sarhan, R. Karimzadeh, R. Singh, and K. Singh, Analysis of Corrosion Protection Behavior of Al2O3-TiO2 Oxide Ceramic Coating on Carbon Steel Pipes for Petroleum Industry, Ceram. Int., 2018, 44(6), p 5967–5975.10.1016/j.ceramint.2017.12.175 ↗
18. D. Seifzadeh, V. Valizadeh-Pashabeigh, and A. Bezaatpour, 5-CM-Salophen Schiff Base as an Effective Inhibitor for Corrosion of Mild Steel in 0.5 M HCl, Chem. Eng. Commun., 2016, 203(10), p 1279–1287.10.1080/00986445.2016.1188290 ↗
19. L.R. Krishna, Y. Madhavi, P.S. Babu, D.S. Rao, and G. Padmanabham, Strategies for Corrosion Protection of Non-ferrous Metals and Alloys through Surface Engineering, Mater. Today Proc., 2019, 15, p 145–154.10.1016/j.matpr.2019.05.037 ↗
20. H. Singh, B.S. Sidhu, and S. Prakash, Performance of HVOF Sprayed NiCr and Stellite-6 Coatings under Pin on Disc Wear Testing, Mater. Sci. Forum, 2012, 701, p 21–29.10.4028/www.scientific.net/MSF.701.21 ↗
21. P.R. Ammal, M. Prajila, and A. Joseph, Effective Inhibition of Mild Steel Corrosion in Hydrochloric Acid Using EBIMOT, a 1, 3, 4-Oxadiazole Derivative Bearing a 2-Ethylbenzimidazole Moiety: Electro Analytical, Computational and Kinetic Studies, Egypt. J. Pet., 2018, 27(4), p 823–833.10.1016/j.ejpe.2017.12.004 ↗
22. M.S. Storozhenko, A.P. Umanskii, A.E. Terentiev, and I.M. Zakiev, Effect of the Structure of TiB2-(Fe-Mo) Plasma Coatings on Mechanical and Tribotechnical Properties, Powder Metall. Met. Ceram., 2017, 56(1), p 60–69.10.1007/s11106-017-9872-x ↗
23. K. Orubite-Okorosaye, I.R. Jack, M. Ochei, and O. Akaranta, Synergistic Effect of Potassium Iodide on Corrosion Inhibition of Mild Steel in HCl Medium by Extracts of Nypa Fruticans’ Wurmb, J. Appl. Sci. Environ. Manag., 2007 https://doi.org/10.4314/jasem.v11i2.5498010.4314/jasem.v11i2.54980 ↗
24. E.A. Noor and A.H. Al-Moubaraki, Corrosion Behavior of Mild Steel in Hydrochloric Acid Solutions, Int. J. Electrochem. Sci., 2008, 3(1), p 806–818.10.1016/S1452-3981(23)15485-X ↗
25. S.O. Seidu and B.J. Kutelu, Effect of Heat Treatments on Corrosion of Welded Low-carbon Steel in Acid and Salt Environments, J. Miner. Mater. Charact. Eng., 2013, 1, p 95–100.
26. G. Moretti, F. Guidi, and F. Fabris, Corrosion Inhibition of the Mild Steel in 0.5 M HCl by 2-Butyl-Hexahydropyrrolo [1, 2-b][1, 2] Oxazole, Corros. Sci., 2013, 76, p 206–218.10.1016/j.corsci.2013.06.044 ↗
27. A. Sheikh Idrees and A. Sheikh Nazir, Corrosion Behaviour OF HVOF Deposited Zn-Ni-Cu and Zn-Ni-Cu-TiB2 Coatings on Mild Steel, Corros. Rev., 2022 https://doi.org/10.1515/corrrev-2021-008210.1515/corrrev-2021-0082 ↗
28. H.J. Habeeb, H.M. Luaibi, R.M. Dakhil, A.A.H. Kadhum, A.A. Al-Amiery, and T.S. Gaaz, Development of New Corrosion Inhibitor Tested on Mild Steel Supported by Electrochemical Study, Results Phys., 2018, 8, p 1260–1267.10.1016/j.rinp.2018.02.015 ↗
29. O.S.I. Fayomi and A.P.I. Popoola, Corrosion Propagation Challenges of Mild Steel in Industrial Operations and Response to Problem Definition, J. Phys. Conf. Ser., 2019, 1378(2), p 022006.10.1088/1742-6596/1378/2/022006 ↗
30. B.O. Odio, E.C. Chinwuko, J.L. Chukwuneke, and J.E. Sinebe, Investigation of the Effect of Corrosion on Mild Steel in Five Different Environments, Int. J. Sci. Technol. Res., 2014, 3, p 306–310.
31. S.I. Ali and S.N. Ahmad, Erosion Behavior of Zn-Ni-Cu and Zn-Ni-Cu-TiB2 Coated Mild Steel, J. Mater. Eng. Perform., 2022. https://doi.org/10.1007/s11665-022-07657-910.1007/s11665-022-07657-9 ↗