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Milz MP, Wirtz A, Abdulgader M, Biermann D, Tillmann W, Walther F. Fatigue Assessment of Twin Wire Arc Sprayed and Machine Hammer-Peened ZnAl4 Coatings on S355 JRC+C Substrate. MATERIALS 2022; 15:ma15031182. [PMID: 35161126 PMCID: PMC8838386 DOI: 10.3390/ma15031182] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/14/2021] [Revised: 01/28/2022] [Accepted: 01/30/2022] [Indexed: 02/04/2023]
Abstract
Structural elements for applications in maritime environments, especially offshore installations, are subjected to various stresses, such as mechanical loads caused by wind or waves and corrosive attacks, e.g., by seawater, mist and weather. Thermally sprayed ZnAl coatings are often used for maritime applications, mainly due to good corrosion protection properties. Machine hammer peening (MHP) has the potential to increase fatigue and corrosion fatigue resistance of ZnAl coatings by adjusting various material properties such as hardness, porosity and roughness. This study investigates the fatigue behavior of twin wire arc sprayed and MHP post-treated ZnAl4 coatings. Unalloyed steel (S355 JRC+C) was selected as substrate material and tested as a reference. MHP achieved the desired improvements in material properties with increased hardness, decreased roughness and uniform coating thickness. Multiple and constant amplitude tests have been carried out to evaluate the fatigue capability of coating systems. In the high cycle fatigue regime, the additional MHP post-treatment led to an improvement of the lifetime in comparison to pure sandblasted specimens. The surface was identified as a crack initiation point. ZnAl coating and MHP post-treatment are suitable to improve the fatigue behavior in the high cycle fatigue regime compared to uncoated specimens.
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Affiliation(s)
- Michael P. Milz
- Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany;
- Correspondence: ; Tel.: +49-231-755-8031
| | - Andreas Wirtz
- Institute of Machining Technology (ISF), TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany; (A.W.); (D.B.)
| | - Mohamed Abdulgader
- Materials Engineering (LWT), TU Dortmund University, Leonhard-Euler-Str. 2, 44227 Dortmund, Germany; (M.A.); (W.T.)
| | - Dirk Biermann
- Institute of Machining Technology (ISF), TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany; (A.W.); (D.B.)
| | - Wolfgang Tillmann
- Materials Engineering (LWT), TU Dortmund University, Leonhard-Euler-Str. 2, 44227 Dortmund, Germany; (M.A.); (W.T.)
| | - Frank Walther
- Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany;
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2
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Vinagre PA, Lindén JB, Mardaras E, Pinori E, Svenson J. Probing the correlation between corrosion resistance and biofouling of thermally sprayed metallic substrata in the field. BIOFOULING 2022; 38:147-161. [PMID: 35184621 DOI: 10.1080/08927014.2022.2033736] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/24/2021] [Revised: 01/19/2022] [Accepted: 01/19/2022] [Indexed: 06/14/2023]
Abstract
The correlation between inherent corrosion resistance and biofouling was investigated for five different metallic coatings. Steel panels thermally spray-coated with either aluminium, Monel, bronze or different aluminium alloys were tested in controlled salt mist conditions and electrochemical corrosion tests and subsequently employed at sea. The biofouling of the panels was monitored at different depths (5, 10 and 15 m) at periods ranging from 5 to 12 months. The main macrofouling organisms were quantified and analysed using permutational multivariate analysis. The results indicate a significant difference in fouling pressure between depths and the geographic sites used. No statistically significant link between high corrosion resistance and lower biofouling pressure was observed, indicating that the main marine macrofoulers settled equally well on corrosion resistant and corrosion prone metallic surfaces. This work sheds light on biofouling of thermally sprayed metallic substrata and it characterizes and compares biofouling assemblages from different biogeographical regions in Europe.
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Affiliation(s)
- Pedro A Vinagre
- Department of Marine Environment and Licensing, WavEC Offshore Renewables, Lisbon, Portugal
| | - Johan B Lindén
- Department of Corrosion, RISE Research Institutes of Sweden, Borås, Sweden
| | - Enara Mardaras
- AZTERLAN, Basque Research and Technology Alliance (BRTA), Durango, Spain
| | - Emiliano Pinori
- Department of Corrosion, RISE Research Institutes of Sweden, Borås, Sweden
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Effect of Corrosion Products and Deposits on the Damage Tolerance of TSA-Coated Steel in Artificial Seawater. SURFACES 2022. [DOI: 10.3390/surfaces5010005] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
Abstract
The corrosion module of COMSOL Multiphysics 5.6® software was employed to simulate the influence of the corrosion products and calcareous deposits on the damage tolerance of a Thermally Sprayed Aluminium coating (TSA) in a simulated marine immersion environment. The capacity of TSA to polarise the steel was evaluated by modelling 5%, 50%, and 90% of the sample uncoated’s area (i.e., substrate exposed). Additionally, the consumption of the sacrificial coating was simulated by Arbitrary Lagrangian-Eulerian (ALE) for the geometry of the experimental system. The parameters used in the model were obtained from polarisation curves and Electrochemical Impedance Spectroscopy (EIS) available in the literature. The results are in good agreement with measurements of Open Circuit Potential (OCP) and Corrosion Rate (CR) from experiments reported in previous studies. The model predicted the sacrificial protection offered by TSA as a function of the exposed steel surfaces, indicating the ability of TSA coating to polarise steel even with up to 90% damage. Furthermore, a 90–70% reduction in the corrosion rate of TSA was calculated with the simultaneous influence of corrosion products and deposits formed after 20 days of exposure to artificial seawater at room temperature.
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Evaluating the Performance of Aluminum Sacrificial Anodes with Different Concentration of Gallium in Artificial Sea Water. COATINGS 2022. [DOI: 10.3390/coatings12010053] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
In this manuscript, the influence of gallium content additions of Al-Zn-In-Mg alloy was investigated through electrochemical techniques and microstructure observation in 3.5 wt% NaCl solution. The results indicated that Al-Zn-In-Mg-0.03Ga alloy has the best discharge performance among all alloys. We propose that this is due to the fact that gallium addition to the Al-4Zn-In-Mg alloy improves the discharge activity of the alloy as well as elevating its anodic efficiency. In particular, the effect of gallium addition to improve discharge activity tends to be a parabolic curve, in which there is an increase when the gallium is first added that rises to the maximum anode current efficiency of about 98.25% whenever gallium content is 0.03 wt%.
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Thermally Assisted Machine Hammer Peening of Arc-Sprayed ZnAl-Based Corrosion Protective Coatings. JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING 2021. [DOI: 10.3390/jmmp5040109] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Structural elements of offshore facilities, e.g., offshore wind turbines, are subject to static and dynamic mechanical and environmental loads, for example, from wind, waves, and corrosive media. Protective coatings such as thermal sprayed ZnAl coatings are often used for protection, mainly against corrosive stresses. The Machine Hammer Peening (MHP) process is an innovative and promising technique for the post-treatment of ZnAl coating systems that helps reducing roughness and porosity and inducing compressive residual stresses. This should lead to an enhancement of the corrosion fatigue behavior. In this paper, the effect of a thermally assisted MHP process was investigated. The softening of the coating materials will have a direct effect on the densification, residual porosity and the distribution of cracks. The investigation results showed the influence of thermally assisted MHP on the surface properties, porosity, residual stresses, and hardness of the post-treated coatings. The best densification of the coating, i.e., the lowest porosity and roughness and the highest compressive residual stresses, were achieved at a process temperature of 300 °C. A further increase in temperature on the other hand caused a higher porosity and, in some cases, locally restricted melting of the coating and consequently poorer coating properties.
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Chiang PC, Chen CW, Tsai FT, Lin CK, Chen CC. Hard Anodization Film on Carbon Steel Surface by Thermal Spray and Anodization Methods. MATERIALS 2021; 14:ma14133580. [PMID: 34206939 PMCID: PMC8269702 DOI: 10.3390/ma14133580] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/12/2021] [Revised: 06/18/2021] [Accepted: 06/24/2021] [Indexed: 11/16/2022]
Abstract
In this paper, we used two mass-produced industrial technologies, namely, thermal spraying and anodization methods, to enhance the surface characteristics of AISI 1045 medium carbon steel for use in special environments or products. The anodic film can effectively improve the surface properties of carbon steel. A sequence of treatments of the carbon steel substrate surface that consist of sandblasting, spraying the aluminum film, annealing, hot rolling, cleaning, grinding, and polishing can increase the quality of the anodized film. This paper proposes an anodization process for the surface of carbon steel to increase the corrosion resistance, hardness, color diversification, and electrical resistance. The resulting surface improves the hardness (from 170 HV to 524 HV), surface roughness (from 1.26 to 0.15 μm), coloring (from metal color to various colors), and corrosion resistance (from rusty to corrosion resistant). The electrochemical corrosion studies showed that the AISI 1045 steel surface with a hard anodized film had a lower corrosion current density of 10-5.9 A/cm2 and a higher impedance of 9000 ohm than those of naked AISI 1045 steel (10-4.2 A/cm2 and 150 ohm) in HCl gas.
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Affiliation(s)
- Pao-Chang Chiang
- School of Dentistry, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan;
- Dental Department, Wan Fang Hospital, Taipei Medical University, Taipei 11696, Taiwan
- Research Center of Digital Oral Science and Technology, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan
| | - Chih-Wei Chen
- Division of Neurosurgery, Department of Surgery, Chi Mei Medical Center, Tainan 71004, Taiwan;
- Department of Occupational Safety and Health, Institute of Industrial Safety and Disaster Prevention, College of Sustainable Environment, Chia Nan University of Pharmacy and Science, Tainan 71710, Taiwan
| | - Fa-Ta Tsai
- Department of Mechanical Engineering, National United University, Miaoli 36003, Taiwan;
| | - Chung-Kwei Lin
- School of Dentistry, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan;
- Research Center of Digital Oral Science and Technology, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan
- Correspondence: (C.-K.L.); (C.-C.C.)
| | - Chien-Chon Chen
- Research Center of Digital Oral Science and Technology, College of Oral Medicine, Taipei Medical University, Taipei 11031, Taiwan
- Department of Energy Engineering, National United University, Miaoli 36003, Taiwan
- Correspondence: (C.-K.L.); (C.-C.C.)
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Khodakarami S, Zhao H, Rabbi KF, Miljkovic N. Scalable Corrosion-Resistant Coatings for Thermal Applications. ACS APPLIED MATERIALS & INTERFACES 2021; 13:4519-4534. [PMID: 33440119 DOI: 10.1021/acsami.0c19683] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/27/2023]
Abstract
Corrosion of metallic substrates is a problem for a variety of applications. Corrosion can be mitigated with the use of an electrically insulating coating protecting the substrate. Thick millimetric coatings, such as paints, are generally more corrosion-resistant when compared to nanoscale coatings. However, for thermal systems, thick coatings are undesirable due to the resulting decrease in the overall heat transfer stemming from the added coating thermal resistance. Hence, the development of ultrathin (<10 μm) coatings is of great interest. Ultrathin inorganic silicon dioxide (SiO2) coatings applied by sol-gel chemistries or chemical vapor deposition, as well as organic coatings such as Parylene C, have great anticorrosion performance due to their high dielectric breakdown and low moisture permeability. However, their application to arbitrarily shaped metals is difficult or expensive. Here, we develop a sol-gel solution capable of facile and controllable dip coating on arbitrary metals, resulting in a very smooth (<5 nm roughness), thin (∼3 μm), and conformal coating of dense SiO2. To benchmark our material, we compared the corrosion performance with in-house synthesized superhydrophobic aluminum and copper samples, Parylene C-coated substrates, and smooth hydrophobic surfaces functionalized with a hydrophobic self-assembled monolayer. For comparison with state-of-the-art commercial coatings, copper substrates were coated with an organo-ceramic SiO2 layer created by an elevated temperature and atmospheric pressure metal organic chemical vapor deposition process. To characterize corrosion performance, we electrochemically investigated the corrosion resistance of all samples through potentiodynamic polarization studies and electrochemical impedance spectroscopy. To benchmark the coating durability and to demonstrate scalability, we tested internally coated copper tubes in a custom-built corrosion flow loop to simulate realistic working conditions with shear and particulate saltwater flow. The sol-gel and Parylene C coatings demonstrated a 95% decrease in corrosion rate during electrochemical tests. Copper tube weight loss was reduced by 75% for the sol-gel SiO2-coated tubes when seawater was used as the corrosive fluid in the test loop. This work not only demonstrates scalable coating methodologies for applying ultrathin anticorrosion coatings but also develops mechanistic understanding of corrosion mechanisms on a variety of functional surfaces and substrates.
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Affiliation(s)
- Siavash Khodakarami
- Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Hanyang Zhao
- Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Kazi Fazle Rabbi
- Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Nenad Miljkovic
- Department of Mechanical Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- Department of Electrical and Computer Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61810, United States
- Material Research Laboratory, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- International Institute for Carbon Neutral Energy Research (WPI-I2CNER), Kyushu University, 744 Motooka, Nishi-ku, Fukuoka 819-0395, Japan
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Dyl T, Starosta R, Rydz D, Koczurkiewicz B, Kuśmierska-Matyszczak W. The Experimental and Numerical Research for Plastic Working of Nickel Matrix Composite Coatings. MATERIALS 2020; 13:ma13143177. [PMID: 32708641 PMCID: PMC7411783 DOI: 10.3390/ma13143177] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/12/2020] [Revised: 07/11/2020] [Accepted: 07/13/2020] [Indexed: 11/28/2022]
Abstract
In the machine, metallurgical, and shipbuilding industries, steel products with alloy and composite coatings based on nickel may be used. It is expedient to improve the physicochemical properties of the surface layer of products as they have a significant roughness value after thermal spraying. It is therefore important to finish the layers applied by flame spraying, where machining is used for this purpose. However, it causes a loss of coating material, which is quite expensive. Therefore, in order to reduce costs and improve the quality of the surface layer, the finishing treatment of nickel-based coatings by means of plastic working is used. Two types of plastic working were proposed: rolling and burnishing. Numerical and experimental tests of the plastic processing of alloy coatings were carried out. The roughness of the coatings after rolling decreased to 1/25 and 30% strengthening of the alloy coating matrix was determined. After burnishing, roughness was reduced to 1/12 and the alloy coatings were strengthened by 25%. Plastic working by rolling and burnishing has a beneficial effect on the surface quality of the workpiece, not only by significantly improving the roughness, but also by increasing the strength properties of the surface layers.
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Affiliation(s)
- Tomasz Dyl
- Department of Marine Maintenance, Faculty of Marine Engineering, Gdynia Maritime University, Morska Street 81-87, 81-225 Gdynia, Poland;
- Correspondence:
| | - Robert Starosta
- Department of Marine Maintenance, Faculty of Marine Engineering, Gdynia Maritime University, Morska Street 81-87, 81-225 Gdynia, Poland;
| | - Dariusz Rydz
- Faculty of Production Engineering and Materials Technology, Czestochowa University of Technology, Armii Krajowej Avenue 19, 42-201 Czestochowa, Poland; (D.R.); (B.K.)
| | - Bartosz Koczurkiewicz
- Faculty of Production Engineering and Materials Technology, Czestochowa University of Technology, Armii Krajowej Avenue 19, 42-201 Czestochowa, Poland; (D.R.); (B.K.)
| | - Wioletta Kuśmierska-Matyszczak
- Faculty of Mechanical Engineering and Computer Science, Czestochowa University of Technology, Armii Krajowej Avenue 21, 42-201 Czestochowa, Poland;
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Abstract
Thermally sprayed aluminium (TSA) coatings provide protection to offshore steel structures without the use of external cathodic protection (CP) systems. These coatings provide sacrificial protection in the same way as a galvanic anode, and thus hydrogen embrittlement (HE) becomes a major concern with the use of high strength steels. The effect of TSA on the HE of steel seems to remain largely unknown. Further, the location of hydrogen in TSA-coated steel has not been explored. To address the above knowledge gap, API 5L X80 and AISI 4137 steel coupons, with and without TSA, were prepared and the amount of hydrogen present in these steels when cathodically polarised to −1.1 V (Ag/AgCl) for 30 days in synthetic seawater was determined. One set of TSA-coated specimens was left at open circuit potential (OCP). The study indicates that the amount of hydrogen present in TSA-coated steel is ~100 times more than the amount found in uncoated steel, and that the hydrogen seems to be largely localised in the TSA layer.
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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 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.
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