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Al/Al2O3 Composite Coating Deposited by Flame Spraying for Marine

Applications: Alumina Skeleton Enhances Anti-Corrosion and Wear
Performances

Article in Journal of Thermal Spray Technology · March 2014

DOI: 10.1007/s11666-014-0056-7

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DOI: 10.1007/s11666-014-0056-7
1059-9630/$19.00  ASM International
Peer Reviewed

Al/Al2O3 Composite Coating Deposited

by Flame Spraying for Marine Applications:
Alumina Skeleton Enhances Anti-Corrosion
and Wear Performances
Jing Huang, Yi Liu, Jianhui Yuan, and Hua Li

(Submitted September 5, 2013; in revised form December 1, 2013)

Here we report aluminum-alumina composite coatings fabricated by flame spraying for potential marine
applications against both corrosion and wear. Microstructure examination suggested dense coating
structures and the evenly distributed alumina splats formed hard skeleton connecting individual Al
splats. The anti-corrosion and wear performance of the coatings were enhanced significantly by the
addition of alumina. Failure analyses of the coatings after accelerated corrosion testing disclosed the
intact alumina skeleton, which prevented further advancement of the corrosion. The results suggest that
there is great potential for the cost-effective Al-Al2O3 coatings with tailorable alumina contents for
application in the marine environment.

Keywords aluminum, alumina, composite coating, corrosion,

selection of coating materials, easy on-site operation, etc.,
flame spraying making it one of the most promising methods in surface
engineering. Extensive studies have shown competitive
capabilities of thermal sprayed coatings in protecting ocean
structures from corrosion in a long term (Ref 11). Multiple
thermal spray methods were successfully employed for
1. Introduction making the coatings, such as arc spray (Ref 2), high velocity
oxy-fuel (HVOF) spray (Ref 12–15), or flame spray (Ref
The booming ocean economy in recent decades cru- 16). Among the thermal sprayed coatings, aluminum coat-
cially demands advanced anti-corrosion technologies for ings proved to be the most economical corrosion protection
marine infrastructures (Ref 1, 2). Cost-effective metals system for the marine environment (Ref 17). However, use
such as carbon and HSLA steels have been widely used for of aluminum coatings is limited, since in most cases marine
constructing marine structures (Ref 3). Steel construc- corrosion always accompanies wear (Ref 18). On-site
tions, such as drilling platforms and sea bridges, encounter exposure testing has already clearly shown that the well-
severe corrosion damage in the marine environment performed coatings in less-wear environment did not meet
(Ref 4), among which the splash zone is generally con- the demands for protection in the splash zone (Ref 19),
sidered to be the most corrosive environment (Ref 5, 6). which involves more wear-associated erosion. Carbide
Nowadays, the most effective strategy for mitigating cor- coatings have, therefore, been developed to combat both
rosion is coating technique, since coatings on marine the corrosion and wear in marine engineering (Ref 20). The
structures are capable of accomplishing sacrificial corro- coatings, however, raise cost issues, since they are usually
sion protection, physical isolation protection, etc (Ref 2, 7, deposited by expensive HVOF process (Ref 12–15).
8). Numerous methods have been developed for fabri- Alternative wire arc spray or flame spray technique is much
cating the protective coatings, and the most extensively cheaper, but the coatings are poor in wear resistance. Novel
used protecting technique against marine corrosion is the coatings deposited by efficient approaches for combined
use of organic coatings (Ref 9, 10). However, corrosion super corrosion/wear resistance are needed.
progression in the defects inherent in organic coatings Understanding the failure mechanism is essential for
affects their functional service life (Ref 2, 9). Thermal selecting appropriate coating materials and designing the
spraying offers the advantages of cost efficiency, wide coating structure to resist damage in the marine environ-
ment. As one of the key reasons accounting for the failure
of steel structures in the marine environment, corrosion is
Jing Huang, Yi Liu, Jianhui Yuan, and Hua Li, Key Laboratory usually categorized into two basic types, namely galvanic
of Marine Materials and Related Technologies, Zhejiang Key corrosion and stray current corrosion, both of which are
Laboratory of Marine Materials and Protective Technologies, related to electrochemical corrosion (Ref 2, 21, 24).
Ningbo Institute of Materials Technology and Engineering,
Chinese Academy of Sciences, Ningbo 315201, China. Contact
Despite the electrochemical reaction-induced corrosion,
e-mail: [email protected]. due to its higher corrosion potential than iron, aluminum

676—Volume 23(4) April 2014 Journal of Thermal Spray Technology

coating performed well as the barrier and in turn achieved the Al-Al2O3 coatings were deposited by flame spray

Peer Reviewed
sacrificial protection (Ref 7, 8). However, the erosion process (FS-4 system, Wuhan Research Institute of
caused by hard particles for instance sand in flowing Materials Protection, China) and the pure Al coatings
seawater is usually very serious, leading to accelerated were deposited by both flame spray and high velocity arc
corrosion and consequent damage of the coatings. Cor- spray (AS, TLAS-500C, China). The flame spray system
rosion-erosion processes are vastly investigated due to the was specially designed for making coatings of metal alloys
devastating effects that are observed in materials. For and ceramics. For the flame spraying, acetylene was used
metals, corrosion-erosion processes affect engineered as the fuel gas with the flow rate of 1.5 Nm3/h and working
structures such as pipes, diaphragms, offshore to energy pressure of 0.1 MPa. Pressure and flow rate of oxygen
conversion, and many others for marine applications were 0.5 MPa and 2.5 Nm3/h, respectively. The powder
(Ref 22, 23). When corrosion and erosion play together, feed rate was 30 g/min and spray distance was 20 cm. For
the damage of the materials is further deteriorated and the the arc spraying, the current and voltage of the arc were
degradation mechanisms are complex (Ref 24). When set at 80-100 A and 25 V, respectively, and the spray
metal is subjected to hard particle impact, erosion causes distance was 15 cm. The compressed air with the pressure
rupture or removal of the protective film from the metal of 0.5 MPa was used for the arc spraying.
surface, leaving the metallic substrate exposed to erosive
solution (Ref 25). Protective coatings with excellent anti-
2.2 Testing Methods
corrosion and pronounced anti-wear performances are,
therefore, required. Alumina (Al2O3), a typical hard Phases in the powder and the coatings were detected by
ceramic with outstanding properties like low density, high x-ray diffraction (XRD, PANalytical XÕpert Pro MPD
strength, high wear resistance, and excellent chemical diffractometer, The Netherlands) at a scan rate of 0.02/s
stability, is of tremendous potential in the field of anti- over a 2h range of 20-80 using Cu Ka radiation operated
friction/wear applications (Ref 26, 27). In this paper at 35 mA and 40 kV. Topographical and cross-sectional
we proposed a flame sprayed composite coating with morphology of the coatings was examined by field emis-
enhanced corrosion and wear resistance for potential sion scanning electron microscope (FESEM, Hitachi
marine applications. The composite coatings were depos- S-550N, Japan). Element analyses were carried out by
ited by flame spraying pre-mixed Al-Al2O3 feedstock using energy dispersive x-ray spectra (EDX) equipped
powder. Microstructural characterization of the coatings with the FESEM. The porosity of the coatings was mea-
suggested even distribution of Al2O3 splats in the coatings sured using the Brunauer, Emmett and Teller (BET)
and the splats formed a hard skeleton, preventing effec- method by adsorption of nitrogen gas on ASAP 2020 M
tively further progress of corrosion. In addition, the exis- apparatus at 77.3 K, and the BET surface area was cal-
tence of Al2O3 at the coating surfaces significantly culated over the relative pressure range of 0.05-0.20 MPa.
reinforced wear resistance. The strengthening mechanism For assessing the corrosion resistance of the coatings, the
in both the corrosion and wear resistance was elucidated. neutral salt spray (NSS) testing was conducted according
to the ASTM B117/90 standard (Ref 28). The assessments
were performed using standardized 5% NaCl solution
with the pH value of 6.7-7.2 at room temperature. For
2. Materials and Methods
polarization test, the coating samples with the surface area
of 15 9 10 mm2 were exposed to 3 wt.% NaCl solution
2.1 Deposition of the Coatings
(Ref 21). The polarization curves acquired by scanning the
Commercially available powder of aluminum (Al, potential at a rate of 0.01 V/s from 1.5 to 0.5 V were
Beijing General Research Institute of Mining and Metal- recorded on an electrochemical workstation (M273A,
lurgy, China) and alumina (Beijing Sangyao Technology PARC, USA). A similar copper accelerated acetic acid
Co., China) with the size range of +50-100 and +15-45 lm, salt spray testing was also conducted to disclose the cor-
respectively, were used in this study. Previous preliminary rosion failure mechanisms of the coatings. For the solution
study on Al-Al2O3 coatings (10 wt.%Al2O3, 20 wt.% preparation, one gram of copper chloride dehydrate was
Al2O3, 30 wt.%Al2O3, 40 wt.%Al2O3, 60 wt.%Al2O3, added to 3.8 l of 5% NaCl solution and the pH value of
80 wt.%Al2O3) showed that 20 wt.% of Al2O3 was the the work solution was 3.0 as being adjusted through add-
best percentage for anti-corrosion/wear performances of ing acetic acid. All the coating samples polished using
the flame sprayed Al-based coatings. For deposition of the 1200 mesh sand paper were immersed in the 40 C copper
Al-Al2O3 coating, the Al (80 wt.%) and Al2O3 (20 wt.%) accelerated acetic acid salt solution for several days.
powder were pre-mixed and mechanically blended. To Tribological properties of the coatings were evaluated
avoid uneven distribution of the components in the using a reciprocating-type ball-on-disk tribometer (JLTB-
as-sprayed coatings, the mixed powder was stirred using 02, J&L Tech Co. Ltd, Korea), which was equipped with
compressed air during powder feeding. Mild steel plates an environmental chamber where the relative humidity
with the dimension of 50 9 30 9 4 mm3 were used as the and gaseous environment can be controlled (Ref 29). The
substrates for the coating deposition. Prior to the spraying, tests were performed at room temperature with the rela-
the substrates were surface grit blasted using 60 mesh tive humidity of 70% under a load of 5 N and an average
black fused alumina sand and subsequently degreased by sliding speed of 120 mm/s for 420 s. 304 stainless steel
sonication cleaning in acetone. For comparison purpose, balls with the diameter of 3.5 mm were used as the

Journal of Thermal Spray Technology Volume 23(4) April 2014—677

 counterparts. The coatings and 304 balls were ultrasoni- Dense structure is suggested from their cross-sectional
Peer Reviewed

cally cleaned in acetone prior to the testing and a new ball views. Further, porosity measurement by BET approach
or a new position of the ball was used for each friction test. showed the average porosity of 1.53, 8.29, and 2.61% for
The friction coefficients and sliding time were automati- the AS Al coating, the FS Al coating, and the FS Al-Al2O3
cally recorded during the tests. The test for each sample coating, respectively. Compared with the FS Al coating,
was repeated three times at least. After the tests, wear the composite coating is much denser. For the Al-Al2O3
volume was measured using a profile tester (Alpha-Step composite coatings, it is clear that alumina splats are
IQ, USA) and wear rate was calculated from the following evenly distributed in the coating (Fig. 1c), showing unde-
relationships (Ref 29): tectable flaws at Al/Al2O3 interfaces. XRD detection
suggests negligible oxidation of Al during the AS depo-
V
k¼ ðEq 1Þ sition (Fig. 2). However, the FS Al coating exhibits weak
LD peaks for Al2O3, indicating oxidation of certain amount of
V ¼SH ðEq 2Þ Al during the spraying, which is likely attributed to the
longer dwelling time of Al droplets before flattening/
where K is wear rate, V is wear volume, L is applied solidification upon impingement on pre-coating/substrate.
normal load, D is sliding distance, S is cross-sectional area Due to the inert nature of alumina, its uniform presence in
of wear zone, and H is wear distance. the FS Al coating could enhance the anti-corrosion
properties. Compared to the starting Al-Al2O3 powder,
the FS Al-Al2O3 coating shows the major structure
changes of Al2O3 from a-Al2O3 in the starting powder to
3. Results and Discussion c-A12O3 in the coating. The appearance of c-A12O3 in the
coating reflects the molten state of the powder during the
3.1 Microstructure of the Coatings spraying (Ref 30, 31). The partially melted A12O3 parti-
Dense structure was achieved for the coatings depos- cles may enhance the interfaces between Al and A12O3,
ited by both the flame spraying (FS) and AS (Fig. 1). giving rise to improved coating performances.

Fig. 1 Cross-sectional FESEM views of the Al and Al-Al2O3 coatings deposited by FS and AS, (a) the AS Al coating, (b) the FS Al
coating, and (c) the FS Al-Al2O3 coating

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Fig. 2 XRD patterns of (a) the starting Al powder, (b) the Al-
20 wt.%Al2O3 powder, (c) the AS Al coating, (d) the FS Al
coating, and (e) the FS Al-Al2O3 coating

3.2 Corrosion Resistance of the Coatings

Fig. 3 Anti-corrosion testing results of the coatings, (a) poten-
It was well established that corrosion resistance of tiodynamic polarization curves for the pure Al coatings and the
materials is closely related to their corrosion potential and Al-Al2O3 coating measured in 3% NaCl solution, and (b) the
corrosion current density (Ref 32). The potentiodynamic digital photos of the coatings after 1155 h of neutral salt spray
test (NSS test) showing effective protection of the coatings
polarization curves of the coating samples acquired in 3% against corrosion (i: mild steel plate without coating, ii: the AS Al
NaCl solution show that the FS Al coating has a fairly coating, iii: the FS Al coating, and iv: the FS Al-Al2O3 coating)
negative corrosion potential at 1.263 V (Fig. 3a), which
is comparable to the values reported by Rodriguez et al.
(Ref 32). The corrosion potentials of the FS Al-Al2O3 by corrosion are clearly seen on the surfaces of the
coating and the AS Al coating show increased values, coatings. After 144 h corrosion testing, severe pitting
1.068 and 1.036 V, respectively. Surprisingly, the cor- corrosion is suggested for the pure Al coatings (Fig. 4a-2,
rosion current density of the FS Al-Al2O3 composite b-2). Surprisingly, even after 408 h immersion, the
coating, 2.727 9 106 A/cm2, is significantly lower than Al-Al2O3 coating exhibits intact alumina splats on its sur-
that of FS Al coating, 7.079 9 106 A/cm2, or AS Al face (Fig. 4c-2). Most of the aluminum splats have already
coating, 1.026 9 105 A/cm2. This implies that addition of been corroded away (as indicated by the holes shown in
Al2O3 has already enhanced markedly the corrosion Fig. 4c-2 vs. c-1), leaving well-retained alumina splats.
resistance of the Al-based coatings. To further investigate Further morphological examination from the cross-
the anti-corrosion performances of the coatings, they were sections of the coatings after the accelerated corrosion
subjected to the NSS test. After 1155 h testing, the mild evidences progressing path of the corrosion along the
steel plate without coating on it exhibits a lot of rusty through-thickness direction from their surfaces all the way
corrosion products, indicating severe corrosion (Fig. 3b). down to the substrate (Fig. 5a). Strikingly, apart from
The Al-Al2O3 composite coating shows the best perfor- their isolated presence alone, the alumina splats connect
mance among the coatings that there are no white corro- with each other, forming a skeleton-like structure
sion products visible, while the corrosion products in (Fig. 5a). Major part of the aluminum splats located in
flocculent form are clearly seen on the pure Al coatings. between alumina splats were corroded away, but those
Progress has been made in understanding the failure closely contacting with alumina splats are still there. It,
mechanisms of thermal sprayed coatings in corrosive therefore, suggests that the corrosion, in particular pitting
environment. In this study, corrosion regimes of the alu- corrosion, is initiated predominately from the areas of
minum and aluminum-alumina coatings were investigated aluminum splats without contact with alumina splats.
by the accelerated corrosion testing. The typical surface Compared to those areas, the Al/Al2O3 interfaces are
morphologies of the coatings before and after the strong in resisting the corrosion. The materials most sus-
immersion are shown in Fig. 4. Numerous holes induced ceptible to pitting corrosion are usually the ones where

Journal of Thermal Spray Technology Volume 23(4) April 2014—679

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Fig. 4 Typical surface morphologies of the coatings before (1) and after (2) the immersion in the copper accelerated acetic acid salt
solution showing the preferred corrosion of Al and intact Al2O3 splats after the testing, (a-1, a-2) the AS Al coating, (b-1, b-2) the FS Al
coating, and (c-1, c-2) the FS Al-Al2O3 coating. The pure Al coatings (a, b) were immersed in the testing solution for 144 h, while the FS
Al-Al2O3 coating (c) was immersed for 408 h

corrosion resistance is caused by a passivation layer possible formation of a film of oxides on the surface of
(Ref 33). Aluminum is basically active metal, a thin sur- aluminum and in turn destroy the already formed passive
face passivation layer of aluminum oxide has been layers (Ref 36), resulting in local corrosion, i.e., pitting
revealed in the coatings by the XRD detection (Fig. 2). corrosion in this case. When the pits are generated, the
The oxide should be located at periphery of aluminum Cl ions become concentrated in the pits for charge neu-
splat, most likely accounting for the observed phenomena trality and encourage the reaction of positive Al3+ with
that the Al/Al2O3 interfaces are more anti-corrosive. It water to form a hydroxide corrosion product and H+ ions
was claimed that in Ni-Al2O3 composite coating, passiv- (Ref 37). For the current Al/Al2O3 composite coating, the
ation is facilitated by nonconducting alumina particles alumina skeleton structure cuts off the penetration path of
co-deposited with nickel, which contributes to formation Cl ions into the inside of the coating, in turn slowing
of active centers with increased oxygen adsorption (Ref 34), down the advancement of the corrosion.
in turn resulting in increase in anti-corrosion perfor-
mances. The current results agree well with those reported
3.3 Anti-Wear Performances of the Coatings
findings. Based on the microstructural features and eluci-
dation, a schematic model illustrating the corrosion of the The friction coefficient of the pure Al coatings at stable
Al/Al2O3 coating is proposed (Fig. 5b). The unique dis- wear state (either the FS Al coating or the AS Al coating)
tribution of alumina splats in the coating (left half of is ~0.50, while the composite coating shows a value of
Fig. 5b) gives rise to the formation of alumina skeleton ~0.52 (Fig. 6a). The increase in friction coefficient values
that remains almost intact after the corrosion test (right is normal for the composites consisting of hard particles
half of Fig. 5b). As disclosed by the SEM characterization, (Ref 38–40). Significantly reduced wear rate was realized
the extent of the corrosion at top surfaces of the coatings for the alumina-containing coating (Fig. 6b). The wear
is most remarkable. Cl ions in the solution are the main rate of the Al-Al2O3 coating, 8.93 9 104 mm3/N/m, is
factor causing corrosion (Ref 35, 36). The ions hinder about one fifth of those of the pure aluminum coatings.

680—Volume 23(4) April 2014 Journal of Thermal Spray Technology

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Fig. 5 Cross-sectional morphology of the Al-Al2O3 coating after the accelerated corrosion testing showing an inert skeleton structure
constructed by alumina splats (a, a-2 is the magnified view of selected area in a-1), the skeleton resists effectively further progression of
the corrosion (the substance in white color is the corrosion product), and (b) schematic depiction showing the mechanism as to how the
Al2O3 skeleton in the coating resists advancement of corrosion

There is no significant difference in the wear rate and alumina into the Al-based coating, for example, 50 wt.%
friction coefficient between the FS Al coating and the AS alumina, not only resulted in further enhanced wear
Al coating. It is noted that the wear morphology of the resistance, but also introduced the issues of high brittle-
Al-Al2O3 coating differs from that of the pure Al coat- ness and poor cohesion of the coatings (data not shown).
ings (Fig. 6c). Microcracks and deep plowing grooves are Balance among anti-corrosion, anti-wear, and other
observed on the wear tracks of the Al coatings. More mechanical properties are one of the primary concerns
plowed marks were observed on the wear track of the for design and fabrication of the Al-Al2O3 coating for
materials having relatively higher values of wear rate and marine applications. The current cost-effective flame
lower hardness values (Ref 41). In fact, the deep plowing spraying has limitations in spraying ceramic materials,
grooves, ridges, and chips observed on the wear tracks of mainly due to the relatively low flame temperature,
the Al coatings are the features of adhesive wear-domi- ~2000-3000 K. Since the aluminum splats act as binder
nated regimes (Ref 41, 42). While the composite coating entrapping the hard alumina particles, lack of aluminum
shows the wear tracks with relatively narrow width and likely causes poor cohesion of the coatings. In this study,
shallow plowing grooves. Further close microstructural 20 wt.% of alumina was proven to be the appropriate
examination evidenced the predominating fretting wear, proportion for the cost-effective Al-based coatings with
apart from secondary adhesive wear, for the alumina- favorable anti-corrosion and wear properties. The novel
containing coating. The worn morphologies are consistent coatings have great potential for protecting marine
with the wear rates of the coatings. Addition of more structures.

Journal of Thermal Spray Technology Volume 23(4) April 2014—681

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Fig. 6 Wear testing results for the coatings, (a) friction coefficient curves, (b) wear rate of the coatings, and (c) FESEM views of the
worn surfaces of the coatings suggesting the different wear regimes (c-1: the AS Al coating, c-2: the FS Al coating, and c-3: the FS
Al-Al2O3 coating)

4. Conclusions References
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Journal of Thermal Spray Technology Volume 23(4) April 2014—683

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