Research Progress on Preparation of Corrosion-resistant Coatings by Extreme High-speed Laser Material Deposition

doi:10.11902/1005.4537.2023.369

Journal of Chinese Society for Corrosion and protection

2024, Vol. 44

Issue (4): 847-862 DOI: 10.11902/1005.4537.2023.369

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Research Progress on Preparation of Corrosion-resistant Coatings by Extreme High-speed Laser Material Deposition

YANG Haiyun¹, LIU Chunquan¹(

), XIONG Fen¹(

), CHEN Minna¹, XIE Yuelin¹, PENG Longsheng², SUN Sheng³, LIU Haizhou³

1. School of Materials Science and Engineering, Hunan Institute of Technology, Hengyang 421002, China
2. Hunan Lifang Roll Co., Ltd., (Hunan Advanced Manufacturing Engineering Technology Research Center of High Wear-resistant Alloy Materials), Hengyang 421681, China
3. Xin Yu Hua Feng Te Gang Co., Ltd., Xingyu 338099, China

Cite this article:

YANG Haiyun, LIU Chunquan, XIONG Fen, CHEN Minna, XIE Yuelin, PENG Longsheng, SUN Sheng, LIU Haizhou. Research Progress on Preparation of Corrosion-resistant Coatings by Extreme High-speed Laser Material Deposition. Journal of Chinese Society for Corrosion and protection, 2024, 44(4): 847-862.

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Abstract

With the rapid advancement of industrial technology in recent years, there are higher requirements in better surface related performance, such as wear resistance, heat resistance, corrosion resistance etc. for some key industrial equipment components. Extreme high-speed laser material deposition, as an emerging surface treatment technology, it subverts the traditional metal surface treatment process, using high-energy laser as the heat source, alloy powder as the cladding material. It realizes a significant increase in cladding efficiency through the optimal coupling of powder and laser, and improves the surface properties of the workpiece by cladding coating with special properties with high efficiency and excellent surface accuracy, which also provides many advantages for the preparation of corrosion-resistant coatings. This paper firstly summarizes the influence of the chemical composition of coating materials on the corrosion resistance of coatings. Secondly, it summarizes the relation between passivation film, microstructure, dislocations, low-angle grain boundaries, and thermal corrosion kinetics. Thirdly, it reviews the effect of EHLA combined with off-site assisted technology on corrosion resistance. Lastly, it summarizes and outlooks on the enhancement methods of the corrosion resistance of the coatings prepared by ultrahigh-speed laser melting and cladding.

Key words: extreme high-speed laser material deposition corrosion behavior coating

Received: 21 November 2023 32134.14.1005.4537.2023.369

ZTFLH:

TG178

Fund: Hunan Provincial Sci-Tech Talents Sponsorship Program(2023TJ-X10);Hunan Natural Science Foundation(2023JJ50108);Special Science Popularization Thematic Project for the Construction of Innovative Provinces in Hunan Province(2023ZK4316);Hunan Provincial High Wear-resistant Alloy Materials Advanced Manufacturing Engineering Technology Research Center Innovation Capacity Improvement Project(2023ZYQ030);The Characteristic Application Discipline of Material Science and Engineering in Hunan Province (Nos. [2022]351);Hengyang "Xiaohe" Technology Talent Project(Hengshi Kexie Zi [2022] No. 68);Open Project of Science and Technology Innovation Platform of "Mechanical Engineering" Discipline in Hunan Province(KFKA2205);Natural Science Foundation Cultivation Project of Hunan Institute of Technology(2022HY007);National College Student Innovation and Entrepreneurship Training Program Project(S202311528056X)

Corresponding Authors: LIU Chunquan, E-mail: liuchunquan@hnit.edu.cn;

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	Articles by authors
	YANG Haiyun
	LIU Chunquan
	XIONG Fen
	CHEN Minna
	XIE Yuelin
	PENG Longsheng
	SUN Sheng
	LIU Haizhou

URL:

https://www.jcscp.org/EN/10.11902/1005.4537.2023.369 OR https://www.jcscp.org/EN/Y2024/V44/I4/847

Fig.1 STEM analysis results of the microstructure and composition of the coating prepared at the cladding speed of 100 m/min: (a, b) microstructures of the cross-section and the upper surface, respectively, (c) HAADF-STEM image, (d) EDS element mappings of the upper surface, (e, f) line scanning path and element distributions on the upper surface, showing the micro-segregations of Ni and Cr^[16]

Fig.2 Cross-sectional morphology (a) and SEM micrographs (b-f) of CoCrFeNiTiAl _x high-entropy alloy coatings (x = 0 (a, b), 0.5 (c), 1 (d), 1.5 (e) and 2 (f)) ^[29]

Fig.3 Surface morphologies of EHLA-prepared Ni/316L alloy coating without (a) and with (b-e) heat treatments at original (a), 650^oC (b), 700^oC (c), 750^oC (d) and 800^oC (e) after potentiodynamic polarization test^[26]

Fig.4 Depth profiles of Cr, Fe, Ni and O in various coatings: (a) CLA-1, (b) EHLA-1, (c) EHLA-2, (d) EHLA-3^[13]

Fig.5 Cyclic potentiodynamic polarization curves (a) and local enlarged views (b) of EHLA coatings at different scanning speeds ^[39]

Fig.6 Hot corrosion kinetics curves of four coatings in 75%Na₂SO₄ + 25%NaCl molten salt at 900^oC for 60 h: (a) total mass gain, (b) net mass gain^[28]

Fig.7 Polarization curves of CLA coating, EHLA coating and the substrate in 3.5%NaCl solution at room temperature (a), and their corresponding corrosion current densities obtained by Tafel extrapolation (b-d) ^[41]

Fig.8 HAADF-STEM image of the coating prepared by cladding at 100 m/min (a) and corresponding EDS mappings of the upper surface (a1), HAADF-STEM image (b) and corresponding EDS mappings (b1) of the passive film, AFM morphology of the passive film formed on the upper surface (c, c1), HRTEM image (d), corresponding FFT pattern (d1) and SAED pattern (d2) of the passive film, EDS mappings of the passivation film formed on inter-dendrite nucleus (e-e3), EDS mappings of the passivation film formed on dendrite nucleus (f-f3)^{[4, 16]}

Fig.9 Schematic diagram of the formation of the passive film: (a) original surface of the coating, (b) initial formation of the inner layer, (c) formation of the bi-layer passive film^[16]

Fig.10 Corrosion morphologies of the coatings prepared at different cladding speeds after polarization test: (a) 1.5 m/min, (b) 15 m/min, (c) 100 m/min^[14]

Fig.11 Schematic diagrams of nucleation and formation process of the passive film: (a) nucleation on coarsened dendrites, (b) nucleation on refined dendrites, (c) passive film on coarsened dendrites, (d) passive film on refined dendrites^[15]

Fig.12 TEM investigations of the EHLMD coating: (a) Bright-field image, (b) HRTEM image of dislocations in the circle region, (c) HRTEM image of stacking faults, (d) corresponding SAED pattern of the square region^[36]

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