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<p>Nickel coatings are widely employed in industrial applications due to their excellent corrosion resistance and high-temperature stability. Among thermal spray techniques, cold spraying is increasingly preferred for its high deposition rate and ability to produce thick, dense coatings with low porosity while avoiding phase transformations. The corrosion performance of cold-sprayed coatings is primarily governed by inter-splat bonding, which plays a more critical role than the intrinsic properties of the feedstock material. Insufficient inter-splat bonding permits the ingress of corrosive media, leading to localized attack at splat boundaries. Additionally, the microstructure of the coating influences the formation and protective nature of the native oxide layer. This study investigates the effect of initial feedstock condition, specifically grain size variations produced via different atomization techniques, on cold-sprayed nickel coatings' deposition characteristics and corrosion behavior. Microstructural evolution during spraying and subsequent heat treatment was characterized using electron backscatter diffraction (EBSD), and corrosion performance was evaluated by potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) in a 3.5% NaCl solution. Coatings exhibiting severe plastic deformation and improved inter-splat bonding demonstrated enhanced corrosion resistance in the as-sprayed condition. Meanwhile, in heat-treated coatings, improved corrosion resistance is achieved by promoting a uniform grain size distribution, increasing the fraction of low-angle grain boundaries, and enhancing twin density.</p>

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Impact of Initial Feedstock on Corrosion Behavior of Cold-Sprayed Nickel Coatings

  • 期刊论文

  • 发表日期：

    2026年1月8日

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  • G. Neelima Devi,
  • S Kumar,
  • Nitin P. Wasekar,
  • Anjali Kanchi,
  • A. Venu Gopal

摘要

Nickel coatings are widely employed in industrial applications due to their excellent corrosion resistance and high-temperature stability. Among thermal spray techniques, cold spraying is increasingly preferred for its high deposition rate and ability to produce thick, dense coatings with low porosity while avoiding phase transformations. The corrosion performance of cold-sprayed coatings is primarily governed by inter-splat bonding, which plays a more critical role than the intrinsic properties of the feedstock material. Insufficient inter-splat bonding permits the ingress of corrosive media, leading to localized attack at splat boundaries. Additionally, the microstructure of the coating influences the formation and protective nature of the native oxide layer. This study investigates the effect of initial feedstock condition, specifically grain size variations produced via different atomization techniques, on cold-sprayed nickel coatings' deposition characteristics and corrosion behavior. Microstructural evolution during spraying and subsequent heat treatment was characterized using electron backscatter diffraction (EBSD), and corrosion performance was evaluated by potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) in a 3.5% NaCl solution. Coatings exhibiting severe plastic deformation and improved inter-splat bonding demonstrated enhanced corrosion resistance in the as-sprayed condition. Meanwhile, in heat-treated coatings, improved corrosion resistance is achieved by promoting a uniform grain size distribution, increasing the fraction of low-angle grain boundaries, and enhancing twin density.