The effect of sol–gel boehmite coatings on the corrosion and decarburization of C45 steel

Sol–gel boehmite coatings were produced on the polished surfaces of hypo-eutectoid C45carbon steel by dip coating. After the deposition the coatings were heat treated by drying at RT, 150 and 200 °C. It was found that for crack-free coatings, the drying temperature needs to be ≥150 °C. Properly heat-treated boehmite coatings then improve the corrosion resistance of steel, while proposed alumina coatings derived from the boehmite coatings during annealing of the steel affect the decarburization. The coated steel samples were annealed at temperatures that are typical for the heat-treatment and thermomechanical process of C45 steel, i.e., <A_C1 (tempering, sphereoidization) and >A_C3 (austenitization, thermomechanical process). The sol–gel alumina coating decreased the decarburization rate of the quenched steel during the tempering (≤600 °C), which meant that the hardness reduction on the steel surface was smaller. Alumina coatings have a smaller effect on the decarburization at higher temperatures; however, the metallographic analyses indicate that the coatings can retard the oxidation rate in comparison to the decarburization rate and thus, somewhat increase the visual level of the decarburization. Under annealing conditions (T = 950 °C, t = 0.5–2 h) at which the oxidation rate is higher than the decarburization rate the decarburization process is not important since the decarburized layer is peeled off the steel surface together with the scale. No visual decarburization is then observed.