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Salt Spray (Fog) Corrosion Behavior of Cold-Sprayed Aluminum Amorphous/Nanocrystalline Alloy Coating

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Abstract

Aluminum amorphous alloys gained interest in aerospace, automobile and marine industry due to their high specific strength, better wear and corrosion resistances. In the present work, a gas-atomized aluminum amorphous/nanocrystalline alloy powder was deposited on Al-6061 alloy using cold spray technique. The as-sprayed coatings were heat treated at 573K (just below the glass transition temperature, 593K) to obtain a homogenized microstructure. The corrosion behavior of as-sprayed and heat-treated coatings was evaluated under potentiodynamic polarization (ASTM G59-97) and salt fog (ASTM B117) in NaCl medium. The potentiodynamic polarization study revealed a lowest corrosion rate of Al amorphous/nanocrystalline coating in the heat-treated condition than the as-sprayed condition due to reduction in coating defects like porosity and weaker inter-splat regions. The thickness of reaction layer formed during salt fog corrosion tests is 2 to 3 times lower in the case of cold-sprayed Al amorphous/ nanocrystalline coatings as compared to the Al-6061 substrate. The heat-treated coatings have demonstrated a further reduction in the reaction layer thickness. Pitting corrosion forming a porous oxide layer on the surface of bare substrate while a uniform, dense and thin corroded layer was noticed in as-sprayed and heat-treated coatings.

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Authors and Affiliations

  1. International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI) Balapur, Hyderabad, Telanagana, 500 005, India

    P. Suresh Babu, L. Venkatesh, A. Jyothirmayi, K. Suresh, L. Rama Krishna & D. Srinivasa Rao

  2. Nanomechanics and Nanotribology Laboratory, Department of Mechanical and Materials Engineering, Florida International University, Miami, FL-33174, USA

    Arvind Agarwal

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  1. P. Suresh Babu
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  2. L. Venkatesh
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  4. K. Suresh
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  7. D. Srinivasa Rao
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This article is part of a special topical focus in the Journal of Thermal Spray Technology on High Entropy Alloy and Bulk Metallic Glass Coatings. The issue was organized by Dr. Andrew S.M. Ang, Swinburne University of Technology; Prof. B.S. Murty, Indian Institute of Technology Hyderabad; Distinguished Prof. Jien-Wei Yeh, National Tsing Hua University; Prof. Paul Munroe, University of New South Wales; Distinguished Prof. Christopher C. Berndt, Swinburne University of Technology. The issue organizers were mentored by Emeritus Prof. S. Ranganathan, Indian Institute of Sciences.

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Babu, P.S., Venkatesh, L., Jyothirmayi, A. et al. Salt Spray (Fog) Corrosion Behavior of Cold-Sprayed Aluminum Amorphous/Nanocrystalline Alloy Coating. J Therm Spray Tech 31, 1173–1183 (2022). https://doi.org/10.1007/s11666-021-01309-5

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