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Corrosion Resistance of APS- and HVOF-Sprayed Coatings in the Al2O3-TiO2 System

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Abstract

In this article, the results of corrosion investigations performed on thermally sprayed ceramic coatings with different compositions in the Al2O3-TiO2 system (Al2O3, Al2O3-3%TiO2, Al2O3-40%TiO2, and TiO x ) are presented. The coatings were deposited on corrosion-resistant steel substrates using atmospheric plasma spraying (APS) and high-velocity oxy-fuel (HVOF) spraying processes and characterized by means of optical microscopy, scanning electron microscopy (SEM), and x-ray diffraction (XRD). The corrosion properties were investigated in 1 N solutions of NaOH and H2SO4, at room temperature, 60 °C, and 85 °C, as well as in hydrothermal conditions with deionized water at 100 °C and 200 °C. The corrosion stability of the coatings depended on coating characteristics (spraying method, microstructure, and crystalline phase composition) and the corrosive environment (media, test temperature, and duration). In contrast to expectations, APS-sprayed coatings were found to be more corrosion-resistant than the HVOF-sprayed coatings. Addition of TiO2 to Al2O3 increased the corrosion stability, especially for the HVOF-sprayed coatings. In this work, TiO x coatings were found to be more corrosion-resistant than the Al2O3-based coatings.

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Acknowledgments

This work was part of the DVS research project “Corrosion of thermally sprayed oxide-ceramic coatings” (AiF No. 14.966 B), funded via AiF by the Federal Ministry of Economics and Technology within the framework of the program for promotion of “Industrial Joint Research (IGF).” The authors gratefully acknowledge this funding. Thanks are also due to Ms. B. Wolf (Fh-IWS) for metallographic sample preparation.

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Author notes

  1. C. C. Stahr

    Present address: W.C. Heraeus GmbH, Thin Film Materials Division, Wilhelm-Rohn-Strasse 25, 63450, Hanau, Germany

Authors and Affiliations

  1. Fraunhofer Institute for Material and Beam Technology (Fh-IWS), Winterbergstrasse 28, D-01277, Dresden, Germany

    F.-L. Toma, C. C. Stahr, L.-M. Berger & S. Saaro

  2. Fraunhofer Institute for Ceramic Technologies and Systems (Fh-IKTS), Winterbergstrasse 28, D-01277, Dresden, Germany

    M. Herrmann, D. Deska & G. Michael

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  1. F.-L. Toma
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  2. C. C. Stahr
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Correspondence to F.-L. Toma.

Additional information

This article is an invited paper selected from presentations at the 2009 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Expanding Thermal Spray Performance to New Markets and Applications: Proceedings of the 2009 International Thermal Spray Conference, Las Vegas, Nevada, USA, May 4-7, 2009, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2009.

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Toma, FL., Stahr, C.C., Berger, LM. et al. Corrosion Resistance of APS- and HVOF-Sprayed Coatings in the Al2O3-TiO2 System. J Therm Spray Tech 19, 137–147 (2010). https://doi.org/10.1007/s11666-009-9422-2

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  • DOI: https://doi.org/10.1007/s11666-009-9422-2

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