Advanced Coatings for Wear and Corrosion Protection: Session I
Program Organizers: Evelina Vogli, Flame Spray Inc.; Virendra Singh, SLB

Monday 8:00 AM
October 10, 2022
Room: 334
Location: David L. Lawrence Convention Center

Session Chair: Virendra Singh, Schlumberger; Evelina Vogli, LM Group Holdings Inc.


8:00 AM  
Mechanical Property and Corrosion Behavior of Ni-based Coating with Al and Mo Addition: Jaehui Bang1; Junyeop Lee1; Minhye Kang1; Eunkyung Lee1; 1National Korea Maritime and Ocean University
    Applying the surface characteristic improvement process to the marine structures solves the problem caused by the destruction of the passivation film by Cl- ions in the corrosive environment. The most effective method for improving the characteristics is the surface coating using a material with excellent oxidation resistance. Among various ways, twin wire arc spray coating technology is used in many industries for its economic feasibility, high spraying rate, and high deposition efficiency. We performed cyclic potential polarization and immersion tests to verify the effect of coated Ni-5Al, Ni-5.5Al5-Mo, and Ni-20Al on high-strength low-alloy steel. This study confirmed the effect of Al content and Mo addition on corrosion resistance in Ni-based coatings.

8:20 AM  
Coating Properties of Alkyd Resin, Epoxy Resins and Polyurethane Based Nanocomposites: A Review: Ikhazuagbe Ifijen1; Nyaknno U. Udokpoh1; Gregory E. Onaiwu2; Kate E. Mokobia3; Ewanole B. Ohiocheoya1; Osemwekhian Esene1; 1Rubber Research Institute of Nigeria; 2Benson Idahosa University; 3Delta State Polytechnic
    The uniqueness of alkyd resin, epoxy resin and polyurethane nanocomposites has brought prominent recognition to the field of heavy-duty coating materials. This is expected due to the collaborative features of nano-sized materials such as high surface area to volume ratio, great functionality per-unit space, extremely small sizes with high density and that of alkyd resin, epoxy resin and polyurethane (biodegradability, great gloss retention, adaptability, flexibility, durability, good drying properties and weathering resistance). The objective of this review was to analyze the extent and currency of research and the development of alkyd, epoxy and polyurethane nanocomposites in coating applications. The various studied modifications resulted in nanocomposites end-products with much improved properties. However, some challenges to the developments of nanocomposites that need urgent attention are also discussed.

8:40 AM  
Direct Electrodeposition of Corrosion Resistant Coatings onto Aluminum after One Step Surface Pretreatment: Rajeswaran Radhakrishnan1; Timothy Hall1; Maria Inman1; Stephen Snyder1; Cory Crowley2; 1Faraday Technology Inc; 2Fermi National Accelerator Laboratory
    Faraday will describe our recent work on the development of corrosion resistant coatings directly applied to aluminum alloys (6061/4043) after one-step electrochemical surface pretreatment process. Conventional aluminum coating application processes commonly require extensive surface pretreatment processes prior to deposition, owing to aluminum’s reactive nature and affinity for oxygen. In this study we will discuss a simple pretreatment process that enables direct deposition onto Al alloys and can dramatically reduce the cost and challenges associated with the surface preparation of Al. Furthermore, we will discuss the corrosion performance of the Ni, and NiP coatings applied directly to 6061 Al and 4043 Al surfaces. The technology is adaptable to applications that require electrodeposited coatings on passive metals such as aluminum, titanium and stainless steels.

9:00 AM  
Corrosion Resistant Amorphous Based Thermal Sprayed Coatings for Fluoride Molten Salt Environment: Evelina Vogli1; Jinsuo Zhang2; John Kang1; Ricardo Salas1; 1Lm Group Holdings Inc.; 2Virginia Tech
     To achieve high thermal-to-electric conversion efficiency and enable cost competitiveness, the next generation of Nuclear Reactors systems is expected to operate at high temperatures. Molten fluoride salts are identified as a highly promising heat transfer fluid and thermal energy storage media. These molten salts introduce a set of technological and engineering challenges because of their very corrosive characteristics for typical materials. LM Group Holdings, Inc. has developed and applied proprietary innovative amorphous metallic alloy coatings that are able to withstand the severe corrosive environment of molten salt at high temperatures. Amorphous metals are a novel class of materials that have a disordered, non-crystalline, glassy structure This presentation will highlight amorphous thermal sprayed coatings on Haynes 230 which have been tested at Virginia Tech and compared to non-coated Haynes 230 in terms of corrosion resistance under molten fluoride salt. This work is sponsored through DoE SBIR award DE-SC0020761.

9:20 AM  
Evaluation of Wear and Corrosion Performance of Wire Arc Sprayed Al-Si Coating for Marine Applications: Minhye Kang1; Junyeop Lee1; Jaehui Bang1; Eunkyung Lee1; 1Korea Maritime and Ocean University
    Marine environment has significantly high risk of corrosion from Cl ions and dissolved oxygen in seawater, accompanied by wear behavior due to waves and sand. When corrosion and wear occur simultaneously, the interaction between chemical and mechanical action brings about early destruction of parts. To minimize these hazards, surface processing such as thermal spray coating is applied in many cases. In this study, low carbon steel has been coated with aluminum by thermal spray process. Al coatings with different Si content (Pure Al, 94Al-6Si, and 88Al-12Si) were investigated. Cyclic potentiodynamic polarization, galvanic corrosion test and immersion test were performed for investigation of corrosion properties. To evaluate the wear properties of corroded coating, wear tests were conducted to as-sprayed and corroded coatings.

9:40 AM  
Optimization of the Microstructure and Performance of Aluminum Alloy Cold Spray Coatings on Magnesium Alloy Substrates: Sridhar Niverty1; Rajib Kalsar1; Anthony Naccarelli2; Timothy Eden2; Vineet Joshi1; 1Pacific Northwest National Laboratory; 2Pennsylvania State University
    The widespread implementation of Magnesium alloys for the automotive industry warrants an improvement in their corrosion performance and their ability to withstand dissimilar material contact under corrosive environments. Solid-phase coating methods offer opportunities to precisely tune the coating microstructure, thickness, and coating-substrate interface. We report on the optimization and characterization of cold spray deposited AA6061 aluminum alloy coatings on AZ91 Magnesium alloy substrates. Coatings with low porosity, high thickness and hardness were achieved through the use of bond coating composed of pre-treated CP-Al powders. The dynamic nature of the cold spray process enabled the formation of a metallurgical bond at the coating-substrate interface, leading to high adhesion strengths. Lastly, the substantial improvement in corrosion performance of the coatings was evaluated over multiple length scales using in situ electrochemical characterization methods and correlative microscopy.

10:00 AM Break

10:20 AM  
Metallurgical and Mechanical Bonding of Al2O3 on Mold Steel and Wear Behavior: Laser Cladding vs. Thermal Spray: Sumin Song1; Taebum Kim1; Sungjin Kim2; Kyuntaek Cho1; 1KITECH; 2Sunchon National University
     As ceramics are considered as one of the most significant materials because of its electrical and thermal properties, the interest in ceramic-metal bonding technology has been highlighted. In plastic injection industry, “Rapid Heating” technique is a useful way to improve the productivity by reducing process cycle time, so stacking ceramics on the injection mold is necessary. For this technique, processes such as thermal spray and laser cladding have been usually used to build ceramic coatings on metals. In this study, an experimental study was carried out to find out the differences in bonding mechanisms and its following mechanical and tribological properties. Ceramic hardness of laser cladding was over 2400Hv and that of thermal spray was 1100Hv. Diverse microstructures were distinguished by OM and SEM and “Dilution” was observed by EPMA analysis. Wear test showed that laser cladded ceramic layer had lower wear rate which could be attributed to higher hardness.