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Article

Corrosion Resistance of SAE 5160 Steel Deposited by Duplex Simultaneous Treatment with Hastelloy Cathodic Cage

by
Marcos Cristino de Sousa Brito
1,
Juliermes Carvalho Pereira
2,
Lauriene Gonçalves da Luz Silva
1,
Renan Matos Monção
1,
Ediones Maciel de Sousa
3,
Weslley Rick Viana Sampaio
4,
Igor Oliveira Nascimento
5,
Anthunes Íkaro de Araújo
6,
Michelle Cequeira Feitor
5,
Thercio Henrique de Carvalho Costa
5,6,* and
Rômulo Ribeiro Magalhães de Sousa
1
1
Postgraduate Program in Materials Science and Engineering, Universidade Federal do Piauí (UFPI), Teresina 64049-550, PI, Brazil
2
Department of Mathematics and Physics, Universidade Estadual do Maranhão (UEMA), Caxias 65604-380, MA, Brazil
3
Physics Department, Universidade Federal do Piauí (UFPI), Teresina 64049-550, PI, Brazil
4
Instituto Federal de Educação, Ciência e Tecnologia do Maranhão (IFMA), Timon 65635-468, MA, Brazil
5
Postgraduate Program in Mechanical Engineering, Universidade Federal do Rio Grande do Norte (UFRN), Natal 59078-970, RN, Brazil
6
Postgraduate Program in Materials Science and Engineering, Universidade Federal do Rio Grande do Norte (UFRN), Natal 59078-970, RN, Brazil
*
Author to whom correspondence should be addressed.
Lubricants 2025, 13(4), 177; https://doi.org/10.3390/lubricants13040177
Submission received: 20 February 2025 / Revised: 7 April 2025 / Accepted: 8 April 2025 / Published: 12 April 2025
(This article belongs to the Special Issue Fundamentals and Applications of Tribocorrosion)
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Abstract

SAE 5160 steel, classified as high-strength, low-alloy steel, is widely used in the automotive sector due to its excellent mechanical strength and ductility. However, its inherently low corrosion resistance limits its broader application. This study explores the application of the cathodic cage plasma deposition (CCPD) technique to enhance the corrosion resistance of SAE 5160 steel. The treatment was performed using a Hastelloy cathodic cage under two atmospheric conditions: hydrogen-rich (75%H2/25%N2) and nitrogen-rich (25%H2/75%N2). Comprehensive analyses revealed significant improvements in surface properties and corrosion resistance. The hydrogen-rich condition (H25N) facilitated the formation of Cr0.4Ni0.6 and CrN phases, associated with a nanocrystalline structure (37.6 nm) and a thicker coating (45.5 μm), resulting in polarization resistance over 290 times greater than that of untreated steel. Conversely, nitrogen-rich treatment (H75N) promoted the formation of Fe3N and Fe4N phases, achieving a dense but thinner layer (19.6 μm) with polarization resistance approximately 20 times higher than that of untreated steel. These findings underscore the effectiveness of CCPD as a versatile and scalable surface engineering technique capable of tailoring the properties of SAE 5160 steel for use in highly corrosive environments. This study highlights the critical role of optimizing gas compositions and treatment parameters, offering a foundation for advancing plasma-assisted technologies and alloying strategies. The results provide a valuable framework for developing next-generation corrosion-resistant materials, promoting the longevity and reliability of high-strength steels in demanding industrial applications.
Keywords: cathodic cage; corrosion; duplex simultaneous; Hastelloy; SAE 5160 steel cathodic cage; corrosion; duplex simultaneous; Hastelloy; SAE 5160 steel

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MDPI and ACS Style

Brito, M.C.d.S.; Pereira, J.C.; Silva, L.G.d.L.; Monção, R.M.; de Sousa, E.M.; Sampaio, W.R.V.; Nascimento, I.O.; de Araújo, A.Í.; Feitor, M.C.; Costa, T.H.d.C.; et al. Corrosion Resistance of SAE 5160 Steel Deposited by Duplex Simultaneous Treatment with Hastelloy Cathodic Cage. Lubricants 2025, 13, 177. https://doi.org/10.3390/lubricants13040177

AMA Style

Brito MCdS, Pereira JC, Silva LGdL, Monção RM, de Sousa EM, Sampaio WRV, Nascimento IO, de Araújo AÍ, Feitor MC, Costa THdC, et al. Corrosion Resistance of SAE 5160 Steel Deposited by Duplex Simultaneous Treatment with Hastelloy Cathodic Cage. Lubricants. 2025; 13(4):177. https://doi.org/10.3390/lubricants13040177

Chicago/Turabian Style

Brito, Marcos Cristino de Sousa, Juliermes Carvalho Pereira, Lauriene Gonçalves da Luz Silva, Renan Matos Monção, Ediones Maciel de Sousa, Weslley Rick Viana Sampaio, Igor Oliveira Nascimento, Anthunes Íkaro de Araújo, Michelle Cequeira Feitor, Thercio Henrique de Carvalho Costa, and et al. 2025. "Corrosion Resistance of SAE 5160 Steel Deposited by Duplex Simultaneous Treatment with Hastelloy Cathodic Cage" Lubricants 13, no. 4: 177. https://doi.org/10.3390/lubricants13040177

APA Style

Brito, M. C. d. S., Pereira, J. C., Silva, L. G. d. L., Monção, R. M., de Sousa, E. M., Sampaio, W. R. V., Nascimento, I. O., de Araújo, A. Í., Feitor, M. C., Costa, T. H. d. C., & de Sousa, R. R. M. (2025). Corrosion Resistance of SAE 5160 Steel Deposited by Duplex Simultaneous Treatment with Hastelloy Cathodic Cage. Lubricants, 13(4), 177. https://doi.org/10.3390/lubricants13040177

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