Coatings for Harsh Environments

A special issue of Coatings (ISSN 2079-6412).

Deadline for manuscript submissions: closed (15 January 2020) | Viewed by 74169

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Guest Editor
1. TWI, Granta Park, Cambridge CB21 6AL, UK
2. Materials Innovation Centre, School of Engineering, University of Leicester, Leicester LE1 7RH, UK
Interests: corrosion; coatings; electrochemistry; thermal spraying
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Special Issue Information

Dear Colleagues,

The operation of numerous safety-critical components in industries around the world rely on protective coatings. These coatings often allow process equipment to be purposeful in environments well beyond the operational limit of the uncoated components. Durability, ease of application, repairability, reliability and long-term performance of such coatings are key to their application. Therefore, this Special Issue of Coatings, “Coatings for Harsh Environments” is devoted to research and review articles on the metallic, non-metallic and composite coatings used in aggressive environments.

In particular, the topics of interest include, but are not limited to:

  • Coatings for high temperature and molten salt applications;
  • Coatings for mitigating corrosion in CO2 and H2S environments;
  • Thermal spray and cold spray coatings for aggressive environments;
  • Corrosion, wear and cavitation resistant coatings;
  • Coatings for mitigating marine corrosion;
  • Coatings for deep sea applications;
  • Coatings for nuclear applications;
  • Coating for chemical and petrochemical plants;
  • Coatings for aeroengine turbines;
  • Coatings for applications in space;
  • Coatings for oil sands and other oil and gas exploration and production environments.

Dr. Shiladitya Paul
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Coatings is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Published Papers (14 papers)

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Editorial

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4 pages, 172 KiB  
Editorial
Special Issue: “Coatings for Harsh Environments”
by Shiladitya Paul
Coatings 2020, 10(4), 407; https://doi.org/10.3390/coatings10040407 - 20 Apr 2020
Cited by 5 | Viewed by 2543
Abstract
The operation of numerous safety-critical components in industries around the world relies on protective coatings. These coatings often allow process equipment to be purposeful in environments well beyond the operational limit of the uncoated components. Durability, ease of application, repairability, reliability and long-term [...] Read more.
The operation of numerous safety-critical components in industries around the world relies on protective coatings. These coatings often allow process equipment to be purposeful in environments well beyond the operational limit of the uncoated components. Durability, ease of application, repairability, reliability and long-term performance of such coatings are vital to their application. Therefore, this Special Issue of Coatings, “Coatings for Harsh Environments”, is devoted to research and review articles on the metallic, non-metallic and composite coatings used in aggressive environments. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)

Research

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16 pages, 7056 KiB  
Article
Effect of Microstructural Modifications on the Corrosion Resistance of CoCrFeMo0.85Ni Compositionally Complex Alloy Coatings
by Francesco Fanicchia, Ioana Csaki, Laura E. Geambazu, Henry Begg and Shiladitya Paul
Coatings 2019, 9(11), 695; https://doi.org/10.3390/coatings9110695 - 24 Oct 2019
Cited by 13 | Viewed by 3275
Abstract
A compositionally complex alloy (CCA) was developed in powder form and applied as a coating onto a carbon steels substrate by using thermal spray. The purpose of this study was to investigate the effect of microstructural modification induced by using two different powder [...] Read more.
A compositionally complex alloy (CCA) was developed in powder form and applied as a coating onto a carbon steels substrate by using thermal spray. The purpose of this study was to investigate the effect of microstructural modification induced by using two different powder production methods, mechanical alloying and gas atomisation, onto the corrosion resistance of the coatings for a CoCrFeMo0.85Ni composition. The evolution of microstructure from powders to coatings was analysed using scanning electron microscopy coupled with energy-dispersive spectroscopy and X-ray diffraction. In order to evaluate the corrosion performance of the coatings, electrochemical corrosion tests were performed in a 3.5 wt % NaCl solution at pH = 4. The study demonstrates that the powder production method has a significant influence on the phase composition and, in turn, corrosion behaviour of the resulting coating, with the gas atomising route imparting better corrosion resistance properties. Nevertheless, the appearance of the face-centered cubic (FCC) phase characteristic of the CoCrFeMo0.85Ni alloy within the coating produced from the mechanically alloyed powder, opens the possibility for this powder manufacturing technique to effectively produce compositionally complex alloys. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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15 pages, 7377 KiB  
Article
Phase Evolution and Microstructure Analysis of CoCrFeNiMo High-Entropy Alloy for Electro-Spark-Deposited Coatings for Geothermal Environment
by Sigrun N. Karlsdottir, Laura E. Geambazu, Ioana Csaki, Andri I. Thorhallsson, Radu Stefanoiu, Fridrik Magnus and Cosmin Cotrut
Coatings 2019, 9(6), 406; https://doi.org/10.3390/coatings9060406 - 21 Jun 2019
Cited by 26 | Viewed by 4880
Abstract
In this work, a CoCrFeNiMo high-entropy alloy (HEA) material was prepared by the vacuum arc melting (VAM) method and used for electro-spark deposition (ESD). The purpose of this study was to investigate the phase evolution and microstructure of the CoCrFeNiMo HEA as as-cast [...] Read more.
In this work, a CoCrFeNiMo high-entropy alloy (HEA) material was prepared by the vacuum arc melting (VAM) method and used for electro-spark deposition (ESD). The purpose of this study was to investigate the phase evolution and microstructure of the CoCrFeNiMo HEA as as-cast and electro-spark-deposited (ESD) coating to assess its suitability for corrosvie environments encountered in geothermal energy production. The composition, morphology, and structure of the bulk material and the coating were analyzed using scanning electron microscopy (SEM) coupled with energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The hardness of the bulk material was measured to access the mechanical properties when preselecting the composition to be pursued for the ESD coating technique. For the same purpose, electrochemical corrosion tests were performed in a 3.5 wt.% NaCl solution on the bulk material. The results showed the VAM CoCrFeNiMo HEA material had high hardness (593 HV) and low corrosion rates (0.0072 mm/year), which is promising for the high wear and corrosion resistance needed in the harsh geothermal environment. The results from the phase evolution, chemical composition, and microstructural analysis showed an adherent and dense coating with the ESD technique, but with some variance in the distribution of elements in the coating. The crystal structure of the as-cast electrode CoCrFeNiMo material was identified as face centered cubic with XRD, but additional BCC and potentially σ phase was formed for the CoCrFeNiMo coating. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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15 pages, 3054 KiB  
Article
Experiences with Thermal Spray Zinc Duplex Coatings on Road Bridges
by Ole Øystein Knudsen, Håkon Matre, Cato Dørum and Martin Gagné
Coatings 2019, 9(6), 371; https://doi.org/10.3390/coatings9060371 - 08 Jun 2019
Cited by 10 | Viewed by 4155
Abstract
Road bridges are typically designed with a 100-year lifetime, so protective coatings with very long durability are desired. Thermal spray zinc (TSZ) duplex coatings have proven to be very durable. The Norwegian Public Roads Administration (NPRA) has specified TSZ duplex coatings for protection [...] Read more.
Road bridges are typically designed with a 100-year lifetime, so protective coatings with very long durability are desired. Thermal spray zinc (TSZ) duplex coatings have proven to be very durable. The Norwegian Public Roads Administration (NPRA) has specified TSZ duplex coatings for protection of steel bridges since 1965. In this study, the performance of TSZ duplex coatings on 61 steel bridges has been analyzed. Based on corrosivity measurements on five bridges, a corrosivity category was estimated for each bridge in the study. Coating performance was evaluated from pictures taken by the NPRA during routine inspections of the bridges. The results show that very long lifetimes can be achieved with TSZ duplex coatings. There are examples of 50-year old bridges with duplex coatings in good condition. Even in very corrosive environments, more than 40-year old coatings are still in good condition. While there are a few bridges in this study where the coating failed after only about 20 years, the typical coating failures are due to application errors, low paint film thickness and saponification of the paint. Modern bridge designs and improved coating systems are assumed to increase the duplex coating lifetime on bridges even further. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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18 pages, 5150 KiB  
Article
Hot Corrosion Resistance of Laser-Sealed Thermal-Sprayed Cermet Coatings
by Lidia Baiamonte, Cecilia Bartuli, Francesco Marra, Annamaria Gisario and Giovanni Pulci
Coatings 2019, 9(6), 347; https://doi.org/10.3390/coatings9060347 - 28 May 2019
Cited by 6 | Viewed by 4027
Abstract
Hot corrosion affects the components of diesel engines and gas turbines working at high temperatures, in the presence of low-melting salts and oxides, such as sodium sulfate and vanadium oxide. Thermal-sprayed coatings of nickel–chromium-based alloys reinforced with ceramic phases, can improve the hot [...] Read more.
Hot corrosion affects the components of diesel engines and gas turbines working at high temperatures, in the presence of low-melting salts and oxides, such as sodium sulfate and vanadium oxide. Thermal-sprayed coatings of nickel–chromium-based alloys reinforced with ceramic phases, can improve the hot corrosion and erosion resistance of exposed metals, and a sealing thermal, post-treatment can prove effective in reducing the permeability of aggressive species. In this study, the effect of purposely-optimized high-power diode laser reprocessing on the microstructure and type II hot corrosion resistance of cermet coatings of various compositions was investigated. Three different coatings were produced by high velocity oxy-fuel and was tested in the presence of a mixture of Na2SO4 and V2O5 at 700 °C, for up to 200 h: (i) Cr3C2–25% NiCr, (ii) Cr3C2–25% CoNiCrAlY, and (iii) mullite nano–silica–60% NiCr. Results evidenced that laser sealing was not effective in modifying the mechanism, on the basis of the hot corrosion degradation but could provide a substantial increase of the surface hardness and a significant decrease of the overall coating material consumption rate (coating recession), induced by the high temperature corrosive attack. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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11 pages, 2262 KiB  
Article
Discoloration Resistance of Electrolytic Copper Foil Following 1,2,3-Benzotriazole Surface Treatment with Sodium Molybdate
by Dong-Jun Shin, Yu-Kyoung Kim, Jeong-Mo Yoon and Il-Song Park
Coatings 2018, 8(12), 427; https://doi.org/10.3390/coatings8120427 - 26 Nov 2018
Cited by 3 | Viewed by 5001
Abstract
The copper which an important component in the electronics industry, can suffer from discoloration and corrosion. The electrolytic copper foil was treated by 1,2,3-benzo-triazole (BTA) for an environmentally friendly non-chromate surface treatment. It was designed to prevent discoloration and improve corrosion resistance, consisted [...] Read more.
The copper which an important component in the electronics industry, can suffer from discoloration and corrosion. The electrolytic copper foil was treated by 1,2,3-benzo-triazole (BTA) for an environmentally friendly non-chromate surface treatment. It was designed to prevent discoloration and improve corrosion resistance, consisted of BTA and inorganic sodium molybdate (Na2MoO4). Also the ratio of the constituent compounds and the deposition time were varied. Electrochemical corrosion of the Cu-BTA was evaluated using potentiodynamic polarization. Discoloration was analyzed after humidity and heat resistance conditioning. Surface characteristics were evaluated using scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). Increasing corrosion potential and decreasing current density were observed with increasing Na2MoO4 content. A denser protective coating formed as the deposition time increased. Although chromate treatment under severe humidity (80% humidity, 80 °C, 100 h) provided the highest humidity resistance, surface treatment with Na2MoO4 had better heat discoloration inhibition under severe heat-resistant conditions (180 °C, 10 min). When BTA reacts with Cu to form the Cu-BTA-type insoluble protective film, Na2MoO4 accelerates the film formation without being itself adsorbed onto the film. Therefore, the addition of Na2MoO4 increased anticorrosive efficiency through direct/indirect action. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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36 pages, 23871 KiB  
Article
Corrosion Resistance of Boronized, Aluminized, and Chromized Thermal Diffusion-Coated Steels in Simulated High-Temperature Recovery Boiler Conditions
by Amirhossein Mahdavi, Eugene Medvedovski, Gerardo Leal Mendoza and André McDonald
Coatings 2018, 8(8), 257; https://doi.org/10.3390/coatings8080257 - 24 Jul 2018
Cited by 18 | Viewed by 6823
Abstract
In this study, the high-temperature molten salt corrosion resistance of bare steels and steels with protective coatings, fabricated by thermal diffusion processes (boronizing, aluminizing and chromizing), were investigated and compared. Surface engineering through thermal diffusion can be used to fabricate protective coatings against [...] Read more.
In this study, the high-temperature molten salt corrosion resistance of bare steels and steels with protective coatings, fabricated by thermal diffusion processes (boronizing, aluminizing and chromizing), were investigated and compared. Surface engineering through thermal diffusion can be used to fabricate protective coatings against corrosion, while alleviating issues around possible cracking and spallation that is typical for conventional thermal-sprayed coatings. In this regard, samples of low carbon steel and 316 stainless steel substrates were boronized, chromized, and aluminized through a proprietary thermal diffusion process, while some of the samples were further coated with additional thin oxide and non-oxide layers to create new surface architectures. In order to simulate the actual corrosion conditions in recovery boilers (e.g., from black liquor combustion), the surfaces of the samples sprayed with a modeling salt solution, were exposed to low-temperature (220 C) and high-temperature (600 C) environments. According to microstructural and X-ray diffraction (XRD) studies and results of hardness determination, the coatings with multilayered architectures, with and without additional oxide layers, showed successful resistance to corrosive attack over bare steels. In particular, the samples with boronized and chromized coatings successfully withstood low-temperature corrosive attack, and the samples with aluminized coatings successfully resisted both low- and high-temperature molten salt corrosive attacks. The results of this study conducted for the first time for the thermal diffusion coatings suggest that these coatings with the obtained architectures may be suitable for surface engineering of large-sized steel components and tubing required for recovery boilers and other production units for pulp and paper processing and power generation. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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10 pages, 4219 KiB  
Article
Oxidation Behavior of MoSi2-Coated TZM Alloys during Isothermal Exposure at High Temperatures
by Kwangsu Choi, Young Joo Kim, Min Kyu Kim, Sangyeob Lee, Seong Lee and Joon Sik Park
Coatings 2018, 8(6), 218; https://doi.org/10.3390/coatings8060218 - 11 Jun 2018
Cited by 14 | Viewed by 4362
Abstract
Coating properties and oxidation behaviors of Si pack cementation-coated TZM (Mo-0.5Ti-0.1Zr-0.02C) alloys were investigated in order to understand the stability of the coating layer at high temperatures up to 1350 °C in an ambient atmosphere. After the pack cementation coatings, MoSi2 and [...] Read more.
Coating properties and oxidation behaviors of Si pack cementation-coated TZM (Mo-0.5Ti-0.1Zr-0.02C) alloys were investigated in order to understand the stability of the coating layer at high temperatures up to 1350 °C in an ambient atmosphere. After the pack cementation coatings, MoSi2 and Mo5Si3 layers were formed. When MoSi2-coated TZM alloys were oxidized in air at high temperatures, the Si in the outer MoSi2 layer diffused and formed SiO2. Also, due to the diffusion of Si, the MoSi2 layer was transformed into a columnar shaped Mo5Si3 phase. During isothermal oxidation, the Mo5Si3 phase was formed both within the coated MoSi2 layer and between the MoSi2 and the substrate. The coating properties and the oxidation behavior of the Si pack-coated TZM alloys were discussed along with the identification of growth kinetics. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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15 pages, 21837 KiB  
Article
Influence of Lamellar Interface Morphology on Cracking Resistance of Plasma-Sprayed YSZ Coatings
by Jibo Huang, Weize Wang, Xiang Lu, Shaowu Liu and Chaoxiong Li
Coatings 2018, 8(5), 187; https://doi.org/10.3390/coatings8050187 - 15 May 2018
Cited by 22 | Viewed by 5426
Abstract
Splat morphology is an important factor that influences the mechanical properties and durability of thermal barrier coatings (TBCs). In this study, yttria-stabilized zirconia (YSZ) coatings with different lamellar interface morphologies were deposited by atmospheric plasma spraying (APS) using feedstocks with different particle sizes. [...] Read more.
Splat morphology is an important factor that influences the mechanical properties and durability of thermal barrier coatings (TBCs). In this study, yttria-stabilized zirconia (YSZ) coatings with different lamellar interface morphologies were deposited by atmospheric plasma spraying (APS) using feedstocks with different particle sizes. The influence of lamellar interface roughness on the cracking resistance of the coatings was investigated. Furthermore, the thermal shock and erosion resistance of coatings deposited by two different powders was evaluated. It was found that the particle size of the feedstock powder affects the stacking morphology of the splat that forms the coating. Coatings fabricated from coarse YSZ powders (45–60 μm) show a relatively rough inter-lamellar surface, with a roughness about 3 times greater than those faricated from fine powders (15–25 μm). Coatings prepared with fine powders tend to form large cracks parallel to the substrate direction under indentation, while no cracking phenomena were found in coatings prepared with coarse powders. Due to the higher cracking resistance, coatings prepared with coarse powders show better thermal shock and erosion resistances than those with fine powders. The results of this study provide a reference for the design and optimization of the microstructure of TBCs. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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12 pages, 3036 KiB  
Article
Corrosion Resistance of Pipeline Steel with Damaged Enamel Coating and Cathodic Protection
by Liang Fan, Signo T. Reis, Genda Chen and Michael L. Koenigstein
Coatings 2018, 8(5), 185; https://doi.org/10.3390/coatings8050185 - 14 May 2018
Cited by 24 | Viewed by 6354
Abstract
This paper presents the first report on the corrosion resistance of pipeline steel with damaged enamel coating and cathodic protection in 3.5 wt % NaCl solution. In particular, dual cells are set up to separate the solution in contact with the damaged and [...] Read more.
This paper presents the first report on the corrosion resistance of pipeline steel with damaged enamel coating and cathodic protection in 3.5 wt % NaCl solution. In particular, dual cells are set up to separate the solution in contact with the damaged and intact enamel coating areas, to produce a local corrosion resistance measurement for the first time. Enamel-coated steel samples, with two levels of cathodic protection, are tested to investigate their impedance by electrochemical impedance spectroscopy (EIS) and their cathodic current demand by a potentiostatic test. Due to its glass transition temperature, the enamel-coated pipeline can be operated on at temperatures up to 400 °C. The electrochemical tests show that cathodic protection (CP) can decelerate the degradation process of intact coating and delay the electrochemical reactions at the enamel-steel interface. However, CP has little effect on the performance of coating once damaged and can prevent the exposed steel from corrosion around the damaged site, as verified by visual inspections. Scanning electron microscopy (SEM) indicated no delamination at the damaged enamel–steel interface due to their chemical bond. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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20 pages, 25338 KiB  
Article
Enhancement of the Corrosion Resistance of 304 Stainless Steel by Cr–N and Cr(N,O) Coatings
by Mihaela Dinu, Emile S. Massima Mouele, Anca C. Parau, Alina Vladescu, Leslie F. Petrik and Mariana Braic
Coatings 2018, 8(4), 132; https://doi.org/10.3390/coatings8040132 - 05 Apr 2018
Cited by 35 | Viewed by 9535
Abstract
Chromium nitride and oxynitride coatings were deposited as monolayers ((Cr–N), Cr(N,O)) and bilayers (Cr–N/Cr(N,O), Cr(N,O)/Cr–N) on 304 steel substrates by reactive cathodic arc method. The coatings were characterised by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectrometry (EDS), surface profilometry, [...] Read more.
Chromium nitride and oxynitride coatings were deposited as monolayers ((Cr–N), Cr(N,O)) and bilayers (Cr–N/Cr(N,O), Cr(N,O)/Cr–N) on 304 steel substrates by reactive cathodic arc method. The coatings were characterised by X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectrometry (EDS), surface profilometry, and scratch tester. The anticorrosive properties of the coatings were assessed by electrochemical tests in 0.10 M NaCl + 1.96 M H2O2, carried out at 24 °C. Cr2N, CrN, and Cr(N,O) phases were identified in the coatings by grazing incidence X-ray diffraction (GI-XRD) measurements. The measured adhesion values ranged from 19 N to 35 N, the highest value being obtained for the bilayer with Cr(N,O) on top. Electrochemical tests showed that Cr(N,O) presence in both mono- and bilayered coatings determined the lowest damage in corrosive solution, as compared to the Cr–N coatings. This improvement was ascribed to the more compact structure, lower coatings porosity, and smoother surface. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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12761 KiB  
Article
Wear Transition of CrN Coated M50 Steel under High Temperature and Heavy Load
by Chi Zhang, Le Gu, Guangze Tang and Yuze Mao
Coatings 2017, 7(11), 202; https://doi.org/10.3390/coatings7110202 - 20 Nov 2017
Cited by 16 | Viewed by 5086
Abstract
The combination of high temperature indentation and wear test provides a useful way to investigate wear of CrN coating and wear transition mechanisms. In this paper, the high temperature hardness of CrN coatings and load bearing capacity, Lb, of CrN coated [...] Read more.
The combination of high temperature indentation and wear test provides a useful way to investigate wear of CrN coating and wear transition mechanisms. In this paper, the high temperature hardness of CrN coatings and load bearing capacity, Lb, of CrN coated M50 disks were determined from spherical indentation at temperatures up to 500 °C. Wear tests with different normal loads were carried out at the same temperatures as the indentation tests. The results show that wear mechanism of CrN coating changes with external load, P, and temperature, T. Under a tested condition of P < Lb and T < 315 °C, abrasive is the dominant wear mechanism for CrN coating. Under a tested condition of P < Lb and T ≥ 315 °C, wear of CrN coating transitions into mild oxidation wear due to the lubricating effect of chromium oxide film. Under a tested condition of P > Lb and T < 315 °C, wear of CrN coating was controlled by coating fracture. Under a tested condition of P > Lb and T ≥ 315 °C, wear of CrN coating transitions into the severe wear mode, due to the tensile fracture of oxidation films, thereby leading to adhesion between CrN coating and tribo-counterpart. The presented method can be helpful in predicting permissible load and working temperature in tribological applications of CrN coating. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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17108 KiB  
Article
Effect of Initial Surface Roughness on Cavitation Erosion Resistance of Arc-Sprayed Fe-Based Amorphous/Nanocrystalline Coatings
by Jinran Lin, Zehua Wang, Jiangbo Cheng, Min Kang, Xiuqing Fu and Sheng Hong
Coatings 2017, 7(11), 200; https://doi.org/10.3390/coatings7110200 - 14 Nov 2017
Cited by 26 | Viewed by 4710
Abstract
The arc spraying process was used to prepare Fe-based amorphous/nanocrystalline coating. The cavitation erosion behaviors of FeNiCrBSiNbW coatings with different surface roughness levels were investigated in distilled water. The results showed that FeNiCrBSiNbW coating adhered well to the substrate, and was compact with [...] Read more.
The arc spraying process was used to prepare Fe-based amorphous/nanocrystalline coating. The cavitation erosion behaviors of FeNiCrBSiNbW coatings with different surface roughness levels were investigated in distilled water. The results showed that FeNiCrBSiNbW coating adhered well to the substrate, and was compact with porosity of less than 2%. With increasing initial surface roughness, the coatings showed an increase in mass loss of cavitation erosion damage. The amount of pre-existing defects on the initial surface of the coatings was found to be a significant factor for the difference in the cavitation erosion behavior. The cavitation erosion damage for the coatings was a brittle erosion mode. The evolution of the cavitation erosion mechanism of the coatings with the increase of the initial surface roughness was micro-cracks, pits, detachment of fragments, craters, cracks, pullout of the un-melted particle, and massive exfoliations. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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Review

Jump to: Editorial, Research

19 pages, 936 KiB  
Review
Sacrificial Thermally Sprayed Aluminium Coatings for Marine Environments: A Review
by Berenika Syrek-Gerstenkorn, Shiladitya Paul and Alison J Davenport
Coatings 2020, 10(3), 267; https://doi.org/10.3390/coatings10030267 - 12 Mar 2020
Cited by 30 | Viewed by 6794
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) [...] Read more.
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. Full article
(This article belongs to the Special Issue Coatings for Harsh Environments)
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