Electrochemical Corrosion Resistance of Al₂O₃–YSZ Coatings on Steel Substrates

Abstract

Ceramic materials as coatings are known to have very good corrosion resistance properties compared to metallic or organic coatings, regardless of environmental conditions. The following samples were used for the experiments: an initial steel substrate and Al2O3 + YSZ (12.5%; 25% and 37.5% wt) atmospheric plasma spray-coated samples. The open circuit potential showed similar average values for all samples coated with ceramic layers, which were slightly higher than the potential of the original uncoated sample. The corrosion current densities (icorr) of all plasma jet sputter-coated systems were very similar and significantly lower than those of the original material. Corrosion rates were much lower in the coated systems due to the chemical inertness of the ceramic coatings, particularly alumina- and zirconia-based coatings. It was observed that ceramic layers improve the corrosion resistance of the metallic material, especially at higher percentages of YSZ in the plasma spray-deposited complex layer. The porosity of the sputter-deposited layers reduced their corrosion resistance due to the contact between the electrolyte solution and the metal substrate created by the interconnection of the pores. The complex equivalent electrical circuit chosen for the analysis of the values led to results in accordance with the experimental parameters.

Keywords

• plasma spraying
• corrosion resistance
• ceramic coatings
• structural analysis
• SEM
• EDS