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Wednesday, May 16, 2007 - 4:40 PM

Properties of HVOF Sprayed Ferrous Coatings for Corrosion Protection

J. Zwick, F. Ernst, G. Hidalgo, Surface Engineering Institute, RWTH Aachen University, Aachen, Germany; K. Bobzin, E. Lugscheider, Surface Engineering Institute (IOT), RWTH Aachen University, Aachen, Germany

Increase of commodity prices for classical corrosion protection materials such as WC/Co and Cr3C2/NiCr are leading to significantly increased coating costs. This is resulting in considerably reduced competitiveness compared to other coating technologies such as electroplating, particularly if carbide coatings are representing an overengineered solution for the considered application. A promising economic alternative can be the employment of advanced ferrous materials. Fe-base coatings have the potential for very good corrosion protection and favourable wear properties combined with a low cost level due to relatively low priced alloy materials. In this study three different Fe-base materials have been sprayed by liquid and gaseous fuel HVOF spraying and analysed with respect to microstructure, hardness and corrosion resistance. Corrosion tests have been carried out with sulphuric acid as well as artificial sea water.

Summary: In this study Fe-base materials with three different compositions have been processed with a liquid and a gaseous fuel driven HVOF process. The coatings have been evaluated and compared with respect to microstructure and corrosion performance under different conditions.