Particle Size-Dependent Microstructure, Hardness and Electrochemical Corrosion Behavior of Atmospheric Plasma Sprayed NiCrBSi Coatings
Abstract
:1. Introduction
2. Experimental
2.1. Sample Preparation
2.2. Characterizations
2.3. Electrochemical Measurements
3. Results and Discussion
3.1. Microstructural Features
3.2. Hardness
3.3. Electrochemical Results
3.4. Morphologies of the As-Sprayed Samples after Electrochemical Tests
3.5. Mechanism for Particle Size Induced Distinctions
4. Conclusions
- (1)
- The use of powders with different sizes results in distinctive microstructures, including porosities, the volume fractions of amorphous phases and the number of non-bonded boundaries. The as-sprayed NiCrBSi coatings prepared from the powder with sizes of 50–75 μm (denoted as 50–75C) and 75–100 μm (denoted as 75–100C) exhibits different porosities (2.0 ± 0.8% for 50–75C and 3.0 ± 1.6% for 75–100C, respectively). The as-sprayed 50–75C has a lower hardness (700 ± 41 HV0.5) than the as-sprayed 75–100C (760 ± 74 HV0.5) in spite of the lower porosity. This is attributed to the larger volume fraction of the amorphous phase (15.5%) in the as-sprayed 50–75C compared with that of the counterpart (8.7%), which results from the higher melting degree of small in-flight particles. After eliminating the amorphous phase in the coatings by heat treatment, the porosity becomes the main factor that affects the hardness of the annealed NiCrBSi coatings. Hence, the annealed 50–75C shows a higher hardness (850 ± 111 HV0.5) than the annealed 75–100C (800 ± 82 HV0.5).
- (2)
- Due to the smaller powder used, a greater number of non-bonded boundaries are present in the as-sprayed 50–75C, leading to the easier penetration of corrosive media. Therefore, the as-sprayed 50–75C has higher corrosion current density (0.254 ± 0.062 μA/cm2) than the as-sprayed 75–100C (0.189 ± 0.069 μA/cm2). Correspondingly, the charge transfer resistance of the as-sprayed 50–75C (0.37 ± 0.07 MΩ cm2) is also lower than that of the as-sprayed 75–100C (0.50 ± 0.07 MΩ cm2).
- (3)
- The distinctions in the properties of both as-sprayed NiCrBSi coating samples mainly result from using different-sized powders. The same weight of powder would possess a larger total surface area due to the smaller size. Small in-flight particles are prone to be melted in the plasma arc and therefore the 50–75C show a larger volume fraction of the amorphous phase because of the fast solidification on the surface of the substrate. Meanwhile, owing to the limited diffusion between deposited particles, smaller particles also result in a greater number of non-bonded boundaries in the as-sprayed 50–75C, thereby degrading its corrosion resistance.
Author Contributions
Funding
Conflicts of Interest
References
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Element | C | Si | B | Cr | Fe | Ni |
---|---|---|---|---|---|---|
Wt.% | 0.7~1.1 | 3.2~5.0 | 3.0~3.8 | 17.0~19.0 | <5.0 | Bal. |
Spray Parameter | Measurement |
---|---|
Voltage (V) | 50 |
Current (A) | 600 |
Gun traverse rate (mm/s) | 100 |
Main gas Ar (slpm) | 80 |
Feed gas Ar (slpm) | 40 |
Powder feed rate (g/s) | 0.3 |
Spray distance (mm) | 80 |
Sample | Ni | Ni3B | CrB | Cr3C2 | Cr7C3 | Amorphous Phase |
---|---|---|---|---|---|---|
As-sprayed 50–75C | 58.4 | 12.3 | 8.4 | 3.2 | 2.2 | 15.5 |
As -sprayed 75C–100C | 63.3 | 13.5 | 8.9 | 3.5 | 2.1 | 8.7 |
Annealed 50–75C | 66.9 | 18.4 | 8.8 | 3.5 | 2.4 | Undetected |
Annealed 75C–100C | 67.2 | 18.7 | 8.2 | 3.6 | 2.3 | Undetected |
Sample | Ecorr (mV) | Icorr (μA/cm2) |
---|---|---|
50–75C | −332.7 | 0.243 |
- | −325.3 | 0.184 |
- | −298.1 | 0.334 |
Average value | −318.7 | 0.254 |
Std Dev | 14.9 | 0.062 |
75–100C | −315.8 | 0.134 |
- | −316.9 | 0.149 |
- | −304.2 | 0.286 |
Average value | −312.3 | 0.189 |
Std Dev | 5.7 | 0.069 |
Sample | Rs (Ω cm2) | Rf (Ω cm2) | C × 10−6 (F) | Rct (MΩ cm2) | CPE × 10−6 (Ω−1 cm−2 S−n) | n | W × 10−5 (Ω−1 cm−2 S−0.5) | χ2 × 10−4 |
---|---|---|---|---|---|---|---|---|
50–75C | 11.89 | 11.36 | 2.48 | 0.27 | 39.99 | 0.67 | 6.92 | 7.07 |
8.59 | 9.93 | 3.30 | 0.42 | 36.18 | 0.68 | 14.01 | 9.09 | |
11.79 | 4.21 | 0.95 | 0.41 | 32.56 | 0.66 | 12.77 | 4.39 | |
Average value | 10.76 | 8.50 | 2.24 | 0.37 | 36.04 | 0.67 | 11.23 | 6.85 |
Std Dev | 1.87 | 3.09 | 0.97 | 0.07 | 2.79 | 0.01 | 3.09 | - |
75–100C | 26.99 | 4.13 | 0.74 | 0.59 | 40.95 | 0.67 | 4.43 | 2.91 |
10.54 | 2.63 | 0.66 | 0.41 | 42.41 | 0.68 | 2.95 | 6.16 | |
13.08 | 3.65 | 0.72 | 0.49 | 37.38 | 0.67 | 2.38 | 9.57 | |
Average value | 16.87 | 3.47 | 0.71 | 0.50 | 40.25 | 0.67 | 3.25 | 6.21 |
Std Dev | 8.85 | 0.63 | 0.04 | 0.07 | 2.11 | 0.01 | 0.86 | - |
Points | Location | Na (wt.%) | Cl (wt.%) | Ni (wt.%) | Si (wt.%) | Cr (wt.%) |
---|---|---|---|---|---|---|
A | at the interior of particles | 0.12 | 0.00 | 82.62 | 3.96 | 13.30 |
B | at pores | 7.12 | 13.66 | 47.22 | 5.85 | 26.14 |
C | at the interior of particles | 0.35 | 0.20 | 87.73 | 5.07 | 6.65 |
D | at pores | 17.83 | 8.89 | 26.83 | 1.80 | 44.66 |
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Sang, P.; Chen, L.-Y.; Zhao, C.; Wang, Z.-X.; Wang, H.; Lu, S.; Song, D.; Xu, J.-H.; Zhang, L.-C. Particle Size-Dependent Microstructure, Hardness and Electrochemical Corrosion Behavior of Atmospheric Plasma Sprayed NiCrBSi Coatings. Metals 2019, 9, 1342. https://doi.org/10.3390/met9121342
Sang P, Chen L-Y, Zhao C, Wang Z-X, Wang H, Lu S, Song D, Xu J-H, Zhang L-C. Particle Size-Dependent Microstructure, Hardness and Electrochemical Corrosion Behavior of Atmospheric Plasma Sprayed NiCrBSi Coatings. Metals. 2019; 9(12):1342. https://doi.org/10.3390/met9121342
Chicago/Turabian StyleSang, Peng, Liang-Yu Chen, Cuihua Zhao, Ze-Xin Wang, Haiyang Wang, Sheng Lu, Dongpo Song, Jia-Huan Xu, and Lai-Chang Zhang. 2019. "Particle Size-Dependent Microstructure, Hardness and Electrochemical Corrosion Behavior of Atmospheric Plasma Sprayed NiCrBSi Coatings" Metals 9, no. 12: 1342. https://doi.org/10.3390/met9121342