Corrosion Behavior of Thermal Sprayed ZrO2·38Y2O3 and ZrO2·18TiO2·10Y2O3 Ceramic Coatings with Different Metallic Bonding Layers in Acid Solution

IF 3.2 3区材料科学 Q2 MATERIALS SCIENCE, COATINGS & FILMS

Journal of Thermal Spray Technology Pub Date : 2025-03-06 DOI:10.1007/s11666-025-01972-y

Tianze Xia, Yin Zhuang, Jing Sheng, Jinxing Ni, Jiasheng Yang, Shunyan Tao, Huayu Zhao, Fang Shao

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Abstract

To protect 304L stainless steel from acid corrosion, ZrO₂·38Y₂O₃ and ZrO₂·18TiO₂·10Y₂O₃ ceramic coatings were prepared by atmospheric plasma spraying (APS). CoMoCrSi and CoNiCrAlY were applied as bonding layers between substrates and ceramic coatings using high-velocity oxy-fuel spraying and APS, respectively. By exploring the phase composition, microstructure, and element contents of coatings, combined with corrosion behavior and hardness, it was found that though CoMoCrSi coating had denser microstructure, CoNiCrAlY bonding layer exhibited higher corrosion resistance. Direct contact between the bonding layers and the corrosive medium should be avoided. Compared with HNO₃ solution, H₃PO₄ solution had a stronger influence on the microstructure and hardness. Low corrosion degree of the two ceramic coatings was observed in hydrothermal acid solution. From the perspective of preventing media penetration, ZrO₂·18TiO₂·10Y₂O₃ coating was superior due to the denser microstructure, whereas the own reactivity of ZrO₂·38Y₂O₃ was lower than that of ZrO₂·18TiO₂·10Y₂O₃ coatings in hydrothermal acid solution. After weighing advantages and disadvantages, plasma-sprayed coating with CoNiCrAlY bonding layer and ZrO₂·38Y₂O₃ ceramic coating was considered as a promising material for anti-corrosion applications. Spraying parameter optimization and sealant may further improve its performance. This work can provide insights for further protecting 304L components in acid environments.

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不同金属结合层的热喷涂ZrO2·38Y2O3和ZrO2·18TiO2·10Y2O3陶瓷涂层在酸性溶液中的腐蚀行为

为了防止304L不锈钢被酸腐蚀，采用大气等离子喷涂（APS）法制备了ZrO2·38Y2O3和ZrO2·18TiO2·10Y2O3陶瓷涂层。CoMoCrSi和CoNiCrAlY分别作为基材和陶瓷涂层之间的高速氧燃料喷涂和APS的结合层。通过对镀层的相组成、显微组织和元素含量的研究，结合腐蚀行为和硬度，发现CoMoCrSi涂层的显微组织较致密，CoNiCrAlY结合层的耐蚀性较高。应避免粘接层与腐蚀性介质直接接触。与HNO3溶液相比，H3PO4溶液对显微组织和硬度的影响更大。两种陶瓷涂层在水热酸溶液中的腐蚀程度较低。从防止介质渗透的角度来看，由于ZrO2·18TiO2·10Y2O3涂层的微观结构更致密，因此具有较好的防渗透性能，而ZrO2·38Y2O3涂层自身在水热酸溶液中的反应性要低于ZrO2·18TiO2·10Y2O3涂层。在权衡利弊后，认为等离子喷涂CoNiCrAlY结合层和ZrO2·38Y2O3陶瓷涂层是一种很有前景的防腐材料。喷涂参数的优化和密封胶的使用可进一步提高其性能。这项工作可以为进一步保护酸性环境中的304L组分提供见解。

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来源期刊

Journal of Thermal Spray Technology 工程技术-材料科学：膜

CiteScore

5.20

自引率

25.80%

发文量

198

审稿时长

2.6 months

期刊介绍： From the scientific to the practical, stay on top of advances in this fast-growing coating technology with ASM International''s Journal of Thermal Spray Technology. Critically reviewed scientific papers and engineering articles combine the best of new research with the latest applications and problem solving. A service of the ASM Thermal Spray Society (TSS), the Journal of Thermal Spray Technology covers all fundamental and practical aspects of thermal spray science, including processes, feedstock manufacture, and testing and characterization. The journal contains worldwide coverage of the latest research, products, equipment and process developments, and includes technical note case studies from real-time applications and in-depth topical reviews.