Microstructure Effect of Intermediate Coat Layer on Corrosion Behavior of HVAF-Sprayed Bi-Layer Coatings

The inherent pores and carbides of Cr3C2-NiCr coatings significantly reduce the corrosion resistance, the former by providing preferential paths for ion diffusion and the latter by forming cathodic sites in galvanic couples (between NiCr and Cr3C2). Adding a dense intermediate layer (intermediate coat layer) between the Cr3C2-NiCr coating (top coat) and substrate increases the corrosion protection of the coating if the layer acts as cathode in connection to the top coat. In the present work, NiCr, NiAl, and NiCoCrAlY layers were deposited by high-velocity air-fuel process as intermediate coat layers for the Cr3C2-NiCr top coat. Effects of coating microstructure on corrosion behavior of single- and bi-layer coatings were studied by open-circuit potential and polarization tests in 3.5 wt.% NaCl at room temperature. A zero resistance ammeter technique was used to study the galvanic corrosion of the coupled top and intermediate coat layers. Methods such as SEM and XRD were employed to characterize the as-sprayed and corroded coatings and to investigate the corrosion mechanisms. The results showed that the NiCoCrAlY coating not only presented a more positive corrosion potential (Ecorr) than the Cr3C2-NiCr coating, but also provided a better passive layer than the single-phase NiCr and NiAl coatings.