Influence of Zn and Mg Alloying on the Corrosion Resistance Properties of Al Coating Applied by Arc Thermal Spray Process in Simulated Weather Solution

doi:10.1007/s40195-018-0704-x

Abstract

Abstract:

In this study, Al-Zn and Al-Mg coatings were deposited on steel substrates by an arc thermal spray process. X-ray diffraction and scanning electron microscopy were used to characterize the deposited coatings and corrosion products. Open circuit potential (OCP), electrochemical impedance spectroscopy, and potentiodynamic studies were used to assess the corrosion characteristics of these coatings after exposure according to the Society of Automotive Engineers (SAE) J2334 solution of varying durations. This solution simulates an industrial environment and contains chloride and carbonate ions that induce corrosion of the deposited coatings. However, the Al-Mg alloy coating maintained an OCP of approximately - 0.911 V versus Ag/AgCl in the SAE J2334 solution even after 792 h of exposure. This indicates that it protects the steel sacrificially, whereas the Al-Zn coating provides only barrier-type protection through the deposition of corrosion products. The Al-Mg coating acts as a self-healing coating and provides protection by forming Mg₆Al₂(OH)₁₆CO₃ (Al-Mg layered double hydroxides). Mg₆Al₂(OH)₁₆CO₃ has interlocking characteristics with a morphology of plate-like nanostructures and an ion-exchange ability that can improve the corrosion resistance properties of the coating. The presence of Zn in the corrosion products of the Al-Zn coating allows dissolution, but, at the same time, Zn₅(OH)₆(CO₃)₂ and Zn₆Al₂(OH)₁₆CO₃ are formed and act to reduce the corrosion rate.

Key words: Self-healing coating, Corrosion, Arc thermal spray, Electrochemical impedance spectroscopy

Han-Seung Lee, Seung-Jun Kwon, Jitendra Kumar Singh, Mohamed A. Ismail. Influence of Zn and Mg Alloying on the Corrosion Resistance Properties of Al Coating Applied by Arc Thermal Spray Process in Simulated Weather Solution[J]. Acta Metallurgica Sinica (English Letters), 2018, 31(6): 591-603.

Figures/Tables 14

Table 1 Bond strengths (MPa) of coatings deposited by an arc thermal spray process

Coating ID	Sample no.				Average
Coating ID	1	2	3	4	Average
Al-Zn	4.00	3.99	3.80	3.92	3.93
Al-Mg	5.48	4.86	4.78	4.97	5.02

Fig. 1 SEM images of deposited a Al-Zn, b Al-Mg coatings

Fig. 2 XRD spectra of the deposited coatings

Fig. 3 OCP of coatings measured in SAE J2334 solution with varying exposure periods

Fig. 4 EIS analyses of samples after 1 h of exposure in SAE J2334 solution: a Nyquist, b Bode log modulus-frequency, c Bode phase-frequency plots

Fig. 5 EIS analysis of samples after 24 h of exposure in SAE J2334 solution: a Nyquist, b Bode log modulus-frequency, c Bode phase-frequency plots

Fig. 6 EIS analyses of samples after 216 h of exposure in SAE J2334 solution: a Nyquist, b Bode log modulus-frequency, c Bode phase-frequency plots

Fig. 7 EIS analyses of samples after 792 h of exposure in SAE J2334 solution: a Nyquist, b Bode log modulus-frequency, c Bode phase-frequency plots

Fig. 8 EEC models for coatings exposed in SAE J2334 solution after a 1-24 h, b 216-792 h of exposure

Table 2 Electrochemical parameters extracted after fitting EIS data to suitable EEC for varying exposure periods

Time (h)	Sample ID	R_s (Ω cm²)	R_pore (Ω cm²)	CPE₁		R_ct (Ω cm²)	CPE₂
Time (h)	Sample ID	R_s (Ω cm²)	R_pore (Ω cm²)	Y₁ (1×10^-4) (Ω^-1 cm^-2 s ⁿ )	n ₁	R_ct (Ω cm²)	Y₂ (1×10^-4) (Ω^-1 cm^-2 s ⁿ )	n ₂
1	Al-Zn	63.47	251.01	2.46	0.63	462.91	87.96	0.67
	Al-Mg	78.93	431.46	2.15	0.71	5499	8.12	0.81
24	Al-Zn	65.61	659.58	2.11	0.73	679.1	66.79	0.73
	Al-Mg	85.11	785.8	2.02	0.74	5560.0	5.52	0.81
216	Al-Zn	66.21	1230.2	1.94	0.75	3816.2	42.02	0.77
	Al-Mg	87.56	11,728.0	0.84	0.81	16,789.0	2.93	0.83
792	Al-Zn	81.84	1293.11	1.15	0.79	4789.7	40.53	0.80
	Al-Mg	60.00	18,515	0.47	0.85	27,129.0	1.19	0.87

Fig. 9 Potentiodynamic plots for samples after 792 h of exposure in SAE J2334 solution

Table 3 Potentiodynamic parameters for the coatings after 792 h of exposure in SAE J2334 solution

Coating ID	E_corr (V vs. Ag/AgCl)	I_corr (μA/cm²)	Corrosion rate (μm/y)
Al-Zn	- 0.824	6.45	86.36
Al-Mg	- 0.987	0.497	5.61

Fig. 10 SEM images of corrosion products formed on a Al-Zn, b Al-Mg coatings after potentiodynamic analyses in SAE J2334 solution

Fig. 11 XRD spectra of the corrosion products formed on Al-Zn and Al-Mg coatings after potentiodynamic analyses in SAE J2334 solution

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