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<p>This study examines the micro-structural evolution, wettability, mechanical behavior, and hot corrosion resistance of plasma-sprayed aluminum-based composite coatings reinforced with Al<sub>2</sub>O<sub>3</sub> and MoS<sub>2</sub>. The incorporation of these reinforcements into the aluminum matrix reduced porosity by up to 63%, improving densification and mechanical strength. The composite coatings also exhibited enhanced hydrophobicity, with the aluminum (Al) coating containing 10 wt% Al<sub>2</sub>O<sub>3</sub> and 5 wt% MoS<sub>2</sub> showing a water contact angle of 126°. The combined reinforcement significantly increased micro-hardness and yield strength by 116% and 140&#xa0;MPa, respectively. Immersion corrosion tests in a 3.5 wt% NaCl solution indicated a 75% reduction in the corrosion rate for the Al<sub>2</sub>O<sub>3</sub> and MoS<sub>2</sub> reinforced Al coating, which is attributed to its refined microstructure and improved barrier properties. Hot corrosion testing in Na<sub>2</sub>SO<sub>4</sub>-60% V<sub>2</sub>O<sub>5</sub> at 900&#xa0;°C showed that the Al<sub>2</sub>O<sub>3</sub> and MoS<sub>2</sub> reinforced Al coating developed a dense and protective oxide layer that limited the ingress of corrosive species. These results highlight the potential of the Al<sub>2</sub>O<sub>3</sub> and MoS<sub>2</sub> reinforced Al coating for applications requiring durable, thermally stable protective layers in aggressive environments. </p>

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Exceptional Hot Corrosion Resistance and Hydrophobicity of Aluminium Coatings Reinforced with Al2O3 and MoS2

  • 期刊论文

  • 发表日期：

    2025年12月25日

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  • Praveen Kumar,
  • Subhash Kumar,
  • Uma Batra,
  • Anup Kumar Keshri,
  • Swarnima Singh

摘要

This study examines the micro-structural evolution, wettability, mechanical behavior, and hot corrosion resistance of plasma-sprayed aluminum-based composite coatings reinforced with Al2O3 and MoS2. The incorporation of these reinforcements into the aluminum matrix reduced porosity by up to 63%, improving densification and mechanical strength. The composite coatings also exhibited enhanced hydrophobicity, with the aluminum (Al) coating containing 10 wt% Al2O3 and 5 wt% MoS2 showing a water contact angle of 126°. The combined reinforcement significantly increased micro-hardness and yield strength by 116% and 140 MPa, respectively. Immersion corrosion tests in a 3.5 wt% NaCl solution indicated a 75% reduction in the corrosion rate for the Al2O3 and MoS2 reinforced Al coating, which is attributed to its refined microstructure and improved barrier properties. Hot corrosion testing in Na2SO4-60% V2O5 at 900 °C showed that the Al2O3 and MoS2 reinforced Al coating developed a dense and protective oxide layer that limited the ingress of corrosive species. These results highlight the potential of the Al2O3 and MoS2 reinforced Al coating for applications requiring durable, thermally stable protective layers in aggressive environments.