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Research on the Corrosion Mechanism of Ceramic Composite Coating in Molten Zinc

Author: ZhangRan
Tutor: YanDianRan
School: Hebei University of Technology
Course: Materials Science
Keywords: plasma spray zinc corrosion resistance solid solution ceramic
CLC: TG174.4
Type: Master's thesis
Year: 2010
Downloads: 80
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Abstract


The ceramic composite coating was prepared on the surface of steel tube by plasma spraying alloy powders and ceramic powders in this research. The ceramic composite coating was composed of Fe-Al alloy coating, FeAl2O4/Fe/Al2O3 composite coating and ZrO2 coating. The experimental results indicated that the coating have good corrosion resistance in molten zinc.Considering the real working condition of the ceramic composite coating, Fe-Al alloy was used instead of Ni/Al alloy to form the rough coat. Experimental results indicated that Fe-Al intermetallic compounds could binding well to substrate and has good corrosion resistance in molten zinc and good oxidation resistance comparing with Ni/Al alloy. There was a large difference of thermal expansion coefficient between ZrO2 ceramic coating and Fe-Al alloy coating. In order to release the stress of coatings the FeAl2O4/Fe/Al2O3 coating which is formed by metal ceramic composite materials was added between them. The FeAl2O4/Fe/Al2O3 coating has good corrosion resistance in molten zinc and prolong the service life of the ceramic composite coating.The Fe-Al alloy coating was prepared, its’banding strength, oxidation resistance and corrosion resistance was compared with Ni/Al coating. The corrosion behavior of Fe-Al coating in molten zinc was also studied and an opinion was finally concluded that the Fe-Al alloy could dissolve zinc atoms to form solid solution when corrosion started. The Fe-Al-Zn phase would change to Fe-Zn phase.The FeAl2O4/Fe/Al2O3 composite coating was prepared by plasma spraying Fe2O3/Al composite coating and its’phase structure was analysed. The corrosion mechanism and transition of FeAl2O4/Fe/Al2O3 especially the FeAl2O4 phase was studied. According to the experimental results it would change follow the rule that FeAl2O4→Zn（FexAl2-x）O4→ZnO+δ→δ+L→L. After preparing Fe-Al alloy coating and FeAl2O4/Fe/Al2O3 composite coating, the ZrO2 coating was prepared to be the surface layer which have high rigidity and good corrosion resistance. The real service environment of heating tube was simulated and the corrosion experiment was running in this environment. The service life and how it was damaged in molten zinc was studied.At the end of this article a few prospects were made to improve the quality of the ceramic composite coating.

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CLC: > Industrial Technology > Metallurgy and Metal Craft > Metallurgy and Heat Treatment > Metal corrosion protection,metal surface treatment > Corrosion control and protection > Metal surface protection technology
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