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<p>To protect 304L stainless steel from acid corrosion, ZrO<sub>2</sub>·38Y<sub>2</sub>O<sub>3</sub> and ZrO<sub>2</sub>·18TiO<sub>2</sub>·10Y<sub>2</sub>O<sub>3</sub> 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 HNO<sub>3</sub> solution, H<sub>3</sub>PO<sub>4</sub> 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, ZrO<sub>2</sub>·18TiO<sub>2</sub>·10Y<sub>2</sub>O<sub>3</sub> coating was superior due to the denser microstructure, whereas the own reactivity of ZrO<sub>2</sub>·38Y<sub>2</sub>O<sub>3</sub> was lower than that of ZrO<sub>2</sub>·18TiO<sub>2</sub>·10Y<sub>2</sub>O<sub>3</sub> coatings in hydrothermal acid solution. After weighing advantages and disadvantages, plasma-sprayed coating with CoNiCrAlY bonding layer and ZrO<sub>2</sub>·38Y<sub>2</sub>O<sub>3</sub> 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.</p>

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

  • 期刊论文

  • 发表日期：

    2025年3月6日

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

摘要

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.