In the present study, nanocrystalline CoNiCrAlY powder has been synthesized by mechanical milling and has been subjected to coating on INCONEL 718 substrate by high velocity oxyfuel (HVOF) and air plasma spraying (APS) techniques. Followed by coating, a detailed evaluation of the corrosion behavior of the coated surface has been carried out in a 3.56 wt.% NaCl solution by potentiodynamic polarization study and electrochemical impedance spectroscopy. Commercially available CoNiCrAlY powder was milled for 10 and 25 h using stearic acid as a process control agent (PCA) in a tungsten carbide (WC) ball and vial at a speed of 300 RPM. A 150 μm thick coating of both as-received and milled powders was sprayed onto Inconel 718 substrate pre-treated by sand blasting. The microstructure of the coating consists of γ (Co, Ni, Cr), γ′(Co, Ni)3Al, and β (Co, Ni)Al phases. A significant improvement in corrosion resistance was observed in the coating with 25 h milled CoNiCrAlY as compared to the as-received one due to the uniform distribution of β phase along the matrix. The study established a relationship between corrosion resistance, crystallite size, and microstructure, highlighting how these factors influence the overall performance of coatings. A comparison of the coating shows that the HVOF coating offered a superior corrosion resistance than plasma spraying. It also compared the benefits of mechanical milling in improving the properties of coatings applied using High-Velocity Oxy-Fuel (HVOF) and Air Plasma Spray (APS) techniques.
WangJXuJZhangX, et al. An investigation of surface corrosion behavior of Inconel 718 after robotic belt grinding. Materials. 2018; 11(12): 2440: 1–14. DOI: 10.3390/ma11122440
2.
KumarMDutta MajumdarJMannaI.Development of Gd2O3 doped yttria stabilized zirconia based thermal barrier coating for improved high temperature oxidation and erosion resistance. Ceram Int2023; 49: 38081–38093.
3.
Tejero-MartinDRezvani RadMMcDonaldA, et al. Beyond traditional coatings: a review on thermal-sprayed functional and smart coatings. J Therm Spray Technol2019; 28: 598–644.
4.
TangYShenXQiaoY, et al. Corrosion behavior of a selective laser melted inconel 718 alloy in a 3.5 wt.% NaCl solution. J Mater Eng Perform2021; 30: 5506–5514.
5.
GuoWWuYZhangJ, et al. Fabrication and characterization of thermal-sprayed Fe-based amorphous/nanocrystalline composite coatings: an overview. J Therm Spray Technol2014; 23: 1157–1180.
6.
KumarANayakSKBijalwanP, et al. Optimization of mechanical and corrosion properties of plasma sprayed low-chromium containing Fe-based amorphous/nanocrystalline composite coating. Surf Coat Technol2019; 370: 255–268.
7.
LuoSHuangWYangH, et al. Microstructural evolution and corrosion behaviors of Inconel 718 alloy produced by selective laser melting following different heat treatments. Addit Manuf2019; 30: 100875.
8.
LiHFengSLiJ, et al. Effect of heat treatment on the δ phase distribution and corrosion resistance of selective laser melting manufactured Inconel 718 superalloy. Mater Corros2018; 69: 1350–1354.
9.
LiuLLiYWangF.Electrochemical corrosion behavior of nanocrystalline materials - a review. Journal of Materials Science and Technology2010; 26(1): 1–14.
10.
HaoELiuXAnY, et al. The coupling effect of immersion corrosion and cavitation erosion of NiCoCrAlYTa coatings in artificial seawater. Corros Sci2020; 169: 108635.
11.
RathodWSKhannaASKarthikeyanJ, et al. Oxidation and corrosion behaviour of CoNiCrAlY bond coats. Surf Eng2014; 30: 432–442.
12.
GarcesHFTranASternlichtH, et al. Sea-salt-induced moderate-temperature degradation of thermally-sprayed MCrAlY bond-coats. Surf Coat Technol2020; 404: 126459.
13.
Ruiz-LunaHPorcayo-CalderonJAlvarado-OrozcoJM, et al. Electrochemical corrosion of HVOF-Sprayed NiCoCrAlY coatings in CO2-saturated brine. J Therm Spray Technol2016; 25: 1330–1343.
14.
IlyasMMehmoodKUmerMA, et al. Revealing microstructure and electrochemical corrosion behaviour of CoNiCrAlY coatings fabricated by supersonic plasma spraying. JOM2024; 76: 3935–3944.
15.
Morales-HernándezJMandujano-RuizACastañeda-ZaldivarF, et al. High temperature corrosion resistance of coatings deposited by hvof for application in steam turbines. Procedia Chem2014; 12: 80–91.
16.
HuangKLiWPanK, et al. Microstructure and corrosion properties of La2Zr2O7/NiCoAlY thermal barrier coatings deposited on inconel 718 superalloy by laser cladding. Coatings2021; 11(1): 12.
17.
WangJChenMChengY, et al. Hot corrosion of arc ion plating NiCrAlY and sputtered nanocrystalline coatings on a nickel-based single-crystal superalloy. Corros Sci2017; 123: 27–39.
18.
BaoZBWangQMLiWZ, et al. Corrosion behaviour of AIP NiCoCrAlYSiB coating in salt spray tests. Corros Sci2008; 50: 847–855.
19.
DashASMannaIDevapalD, et al. Effect of process parameter on the flowability of nanocrystalline CoNiCrAlY powder synthesized by mechanical milling. Particuology2024; 92: 210–223.
20.
JribiFAdenyaCAMutuaJM.Atmospheric corrosion of stainless steel 304. Int J Eng Res Technol2020; 13: 484–489.
21.
RsheedA. ALAldawoodS.AldossaryO. M.The size and shape effects on the melting point of nanoparticles based on the Lennard-Jones potential function. Nanomaterials (Basel)2021; 11(11):2916: 1–12. DOI: 10.3390/nano11112916
22.
PuriPYangV.Effect of particle size on melting of aluminum at nano scales. J Phys Chem C2007; 111: 11776–11783.
23.
GaoFHuangXLiuR, et al. Optimization of plasma spray process using statistical methods. J Therm Spray Technol2012; 21: 176–186.
24.
RicherPYandouziMBeauvaisL, et al. Oxidation behaviour of CoNiCrAlY bond coats produced by plasma, HVOF and cold gas dynamic spraying. Surf Coat Technol2010; 204: 3962–3974.
25.
ChenHFanMLiL, et al. Effects of internal oxide contents on the oxidation and β-phase depletion behaviour in HOVF CoNiCrAlY coatings. Surf Coat Technol2021; 424: 127666.
26.
BinduPThomasS.Estimation of lattice strain in ZnO nanoparticles: X-ray peak profile analysis. J Theor Appl Phys2014; 8: 123–134.
27.
TiwariGPMehrotraRS.Diffusion and melting. In: Defect and Diffusion Forum. Trans Tech Publ, 2008, pp. 23–37.
28.
PalSVelayXSaleemW.Assessing the corrosive effects of unmelted particles in additively manufactured Ti6Al4V: A study in simulated body fluid. Alloy2024; 3: 257–268.
29.
RiedlR.Eine außergewöhnliche Korrosionserscheinung/an extraordinary case of corrosion. Pract Metallogr1990; 27: 533–536.
30.
PanYZhouYCZhouZF, et al. Fabrication, lattice strain, corrosion resistance and mechanical strength of nanocrystalline nickel films. Trans Nonferrous Met Soc China2007; 17: 1225–1229.
31.
AliyuASrivastavaC.Correlation between growth texture, crystallite size, lattice strain and corrosion behavior of copper-carbon nanotube composite coatings. Surf Coat Technol2021; 405: 126596.
32.
TahariMShamanianMSalehiM.The effect of heat treatment and thermal spray processes on the grain growth of nanostructured composite CoNiCrAlY/YSZ powders. J Alloys Comp2015; 646: 372–379.
33.
GuoDZhaoLJodoinB.Cold spray for production of in-situ nanocrystalline MCrAlY coatings – Part II: Isothermal oxidation performance. Surf Coat Technol2021; 409: 126828.
34.
GuoWZhangHZhaoS, et al. Corrosion behavior of the CoNiCrAlY-Al2O3 composite coating based on core-shell structured powder design. Materials. 2021; 14(22), 7093: 1–15. DOI: 10.3390/ma14227093
35.
LasiaA.Electrochemical impedance spectroscopy and its applications. New York: Springer, 2014.
36.
SadeghimereshtEMarkocsanNNylénP.Microstructural and electrochemical characterization of Ni-based bi-layer coatings produced by the HVAF process. Surf Coat Technol2016; 304: 606–619.
37.
MadapanaDBatheRMannaI, et al. Effect of process parameters on the corrosion kinetics and mechanism of nanosecond laser surface structured titanium alloy (Ti6Al4V). Appl Surf Sci Adv2024; 20: 100580.
38.
LisieckiITurnerSBalsS, et al. The remarkable and intriguing resistance to oxidation of 2D ordered hcp Co nanocrystals. A new intrinsic property. Chem Mater2009; 21: 2335–2338.
39.
WangWMuWWeiD, et al. High corrosion resistance duplex fcc + hcp cobalt based entropic alloys: an experimental and theoretical investigation. Mater Des2022; 223: 111166.
DickinsonTPoveyAFSherwoodPMA. Dissolution and passivation of nickel an X-ray photoelectron spectroscopic study. J. Chem. Soc., Faraday Trans. 1, 1977, 73: 327–343.
45.
LiCPProctorAHerculesDM.Curve fitting analysis of ESCA Ni 2p spectra of nickel-oxygen compounds and Ni/Al2O3 catalysts. Appl Spectrosc1984; 38: 880–886.
46.
SolerLCandelaAMMacanásJ, et al. Hydrogen generation by aluminum corrosion in seawater promoted by suspensions of aluminum hydroxide. Int J Hydrogen Energy2009; 34: 8511–8518.
47.
OnyeachuBIOguzieEEUkagaIC, et al. Ni corrosion product layer during immersion in a 3.5% NaCl solution: electrochemical and XPS characterization. Port Electrochimica Acta2017; 35: 127–136.
