Preparation, Wear Resistance, and Corrosion Performance of Arc-Sprayed Zn, Al, and Zn-Al Coatings on Carbon Steel Substrates

Zn-Al coatings have attention to corrosion resistance in marine environments. In this study, Zn and Al single coatings, and Zn-Al mixed coating were obtained by an arc spray technique on carbon steel substrates. Zn and Al coatings comprised single Zn and Al phases, and some oxides. Zn-Al coating was composed of 46 at.% Al, 53 at.% Zn, and a few of oxygen. Zn-Al coating was a pseudo-alloy coating mechanically mixed with Zn, Al, and alloy phases. The cross-sectional microhardness values of Zn, Al, and Zn-Al coatings were 173.8 HV0.5, 181.69 HV0.5, and 259.88 HV0.5, respectively. The friction coefficients of Al, Zn, and Zn-Al coatings were 0.7, 0.55, and 0.5, respectively. The wear and corrosion resistances of Zn-Al coating were better compared with single metallic coatings. The corrosion mechanisms of single Zn, Al coatings, and Zn-Al coatings were addressed and studied. Zn-Al coating could offer better wear resistance and anticorrosion performance for marine engineering steel, compared with Zn and Al coatings.