Corrosion Behavior of Cold Sprayed Zn15Al Alloy Coating on Q235 Carbon Steel in NaCl Aqueous Solution

doi:10.11901/1005.3093.2023.254

Chinese Journal of Materials Research

2024, Vol. 38

Issue (3): 208-220 DOI: 10.11901/1005.3093.2023.254

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Corrosion Behavior of Cold Sprayed Zn15Al Alloy Coating on Q235 Carbon Steel in NaCl Aqueous Solution

XU Long¹(

), LI Jiwen², CUI Chuanyu¹, LU Qi¹, YANG Hao¹, ZHAO Congcong¹

^1.Materials Science and Technology Research Department, Ji Hua Laboratory, Foshan 528200, China
^2.Key Laboratory of Nuclear Materials and Safety Assessment, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

XU Long, LI Jiwen, CUI Chuanyu, LU Qi, YANG Hao, ZHAO Congcong. Corrosion Behavior of Cold Sprayed Zn15Al Alloy Coating on Q235 Carbon Steel in NaCl Aqueous Solution. Chinese Journal of Materials Research, 2024, 38(3): 208-220.

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Abstract

Cold-sprayed coatings Zn (CS-Zn) and Zn15Al alloy (CS-Zn15Al) were prepared on Q235 carbon steel plates via low-pressure cold spraying technique. The corrosion behavior of the coatings in 3.5% NaCl aqueous solution was assessed by means of electrochemical measurement of open circuit potential, electrochemical impedance and potentiodynamic polarization curves, as well as SEM with EDS, XRD. The results indicate that the CS-Zn coating undergoes severe corrosion during immersion, while the CS-Zn15Al coating corrodes at a slower rate and exhibits superior corrosion resistance. XRD results reveal that the dominant corrosion product of CS-Zn is ZnO, which possesses porous structural characteristics that disrupt the compactness of the corrosion product layer. Furthermore, its semiconductor properties decrease the charge transfer resistance, thereby accelerating the process of corrosion. In the contrast, as for CS-Zn15Al, the incorporation of Al facilitates the formation of protective corrosion products, namely Zn₅(OH)₈Cl₂·H₂O and layered double hydroxides Zn₆Al₂(OH)₁₆CO₃·4H₂O. The shielding effect of CS-Zn15Al coating was significantly enhanced by this layer of corrosion products. Furthermore, electrochemical measurements demonstrate that the addition of Al reduces the corrosion potential of the coating, thereby enhancing its cathodic protection ability, and decreases the corrosion current density due to the generation of protective corrosion products. In conclusion, the addition of Al can synergistically enhance the anticorrosion performance and durability of the coating.

Key words: material failure and protection zinc alloy coatings electrochemical impedance spectroscopy cold spraying

Received: 08 May 2023

ZTFLH:

TG174

Fund: Guangdong Basic and Applied Basic Research Foundation(2020A1515110982)

Corresponding Authors: XU Long, Tel:17755333229, E-mail: xulong@jihualab.com

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	XU Long
	LI Jiwen
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	ZHAO Congcong

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https://www.cjmr.org/EN/10.11901/1005.3093.2023.254 OR https://www.cjmr.org/EN/Y2024/V38/I3/208

Fig.1 Morphologies of the Zn (a) and Zn15Al (b) powders observed by SEM backscattering mode (the inset shows the secondary electron image), and the size distribution of Zn (c) and Zn15Al powders (d)

Table 1 Chemical composition of the Zn and Zn15Al alloy powders (%，mass fraction)

Table 2 Chemical composition of Q235 mild steel substrate (%, mass fraction)

Fig.2 Cross-sectional morphologies of the CS-Zn coating (a) coating layer (b) coating/substrate interface, and the corresponding distribution of elements (c) Zn and (d) O

Fig.3 Cross-sectional morphologies of the CS-Zn15Al coating (a) coating layer (b) coating/substrate interface and the corresponding distribution of elements (c) Zn, (d) Al and (e) O

Fig.4 XRD pattern of as-deposited CS-Zn and CS-Zn15Al coatings

Fig.5 Evolution of open circuit potential (a) and low frequency impedance modulus (b) with different immersion time

Fig.6 Cross-sectional morphologies of CS-Zn coating and corresponding elements distribution after 4416 h immersion

Fig.7 Cross-sectional morphologies of CS-Zn15Al coating and corresponding elements distribution after 4416 h immersion

Fig.8 Phase composition characterization of outer (a) and inner (b) layer of corrosion products on of CS-Zn and CS-Zn15Al coating

Fig.9 SEM morphology of outer layer (a, b, e, f) and inner layer (c, d, g, h) of corrosion products

Table 3 Chemical composition analysis of different positions by EDS (mass fraction, %)

Fig.10 Potentiodynamic polarization curves of CS-Zn and CS-Zn15Al coatings at different immersion time (a) 1 h, (b) 17 d, (c) 184 d, and (d) after the removal of surface corrosion products

Fig.11 The evolution of the fitted results for the measured potentiodynamic polarization curves at different immersion times

Fig.12 Evolution of the Nyquist plots of CS-Zn (a) and CS-Zn15Al (b) with different immersion times

Fig.13 Evolution of Bode plots and phase angle of CS-Zn (a, b) and CS-Zn15Al (c, d) with different immersion times

Fig.14 The equivalent circuits used to fit the EIS experimental data obtained at different exposure times (a) initial corrosion stage (b) corrosion stage with corrosion products (c) final corrosion stage for CS-Zn (d) corrosion stage with Warburg impedance (e) final corrosion stage for CS-Zn15Al

Table 4 Fitting results of CS-Zn during the immersion

Table 5 Fitting results of CS-Zn15Al during the immersion

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