Faculty Publications
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Item Corrosion stability of electrodeposited cyclic multilayer Zn-Ni alloy coatings(2011) Bhat, R.S.; Udupa, K.R.; Hegde, A.C.This paper reports on a study of electrodeposition and characterisation of cyclic multilayer coatings of Zn-Ni alloy from a sulphate bath. Cyclic multilayer alloy coatings were deposited on mild steel through the single bath technique by appropriate manipulation of cathode current densities. The thickness and composition of the individual layers of the CMA deposits were altered precisely and conveniently by cyclic modulation of the cathode current during electrodeposition. Multilayer deposits with sharp change in composition were developed using square current pulses, using thiamine hydrochloride and citric acid as additives. Laminar deposits with different configurations were produced and their corrosion behaviours were studied by AC and DC methods in 5%NaCl solution. It was observed that the corrosion resistance of the CMA coating increased progressively with the number of layers (up to certain optimal numbers) and then decreased. The decrease in corrosion resistance at high degree of layering was attributed to interlayer diffusion due to less relaxation time for redistribution of metal ions at cathode during deposition. The coating configurations have been optimised for peak performance of the coatings against corrosion. It was found that CMA coating developed at cyclic cathode current densities of 3.0/5.0 A dm-2 with 300 layers showed the lowest corrosion rate (0.112×10-2 mm/year) which is ?54 times better than that of monolithic Zn-Ni alloy, deposited from the same bath. The protection efficacy of CMA coatings is attributed to the difference in phase structure of the alloys in successive layers, deposited at different current densities, evidenced by X-ray diffraction analysis. The formation of multilayers and corrosion mechanism were examined by scanning electron microscopy. © 2011 Institute of Metal Finishing.Item Surface modification by multilayered Zn-Co alloy coatings(2012) Yogesha, S.; Udupa, K.R.; Hegde, A.Nanostructured multilayer alloy or composition modulated multilayer alloy coatings of Zn-Co have been developed, and their corrosion behaviours were studied by potentiodynamic polarization and electrochemical impedance spectroscopy methods. The coatings were developed galvanostatically using square, triangular and sawtooth current pulses through single bath technique. The cyclic cathode current density and the numbers of layers have been optimised for peak performance of the coatings against corrosion. Under optimal conditions, the coatings developed using square, triangular and sawtooth current pulses were found to be respectively y100, 80 and 90 times more corrosion resistant than monolithic alloy of same thickness. The better corrosion resistances of the composition modulated multilayer alloy coatings were attributed to the dielectric barrier at the interface, as evidenced by dielectric spectroscopy. Surface morphology, multilayer formation and surface after corrosion tests were examined by scanning electron microscopy. © 2012 Institute of Materials, Minerals and Mining.Item Combating corrosion degradation of turbine materials using HVOF sprayed 25% (Cr3C2-25(Ni20Cr)) + NiCrAlY coating(2013) Jegadeeswaran, N.; Ramesh, M.R.; Bhat, K.High velocity oxy fuel process (HVOF) is an advanced coating process for thermal spraying of coatings on to components used in turbines. HVOF process is a thermal spray coating method and is widely used to apply wear, erosion, and corrosion protective coatings to the components used in industrial turbines. 25% (Cr3C2-25(Ni20Cr)) + NiCrAlY based coatings have been sprayed on to three turbine materials, namely, Ti-31, Superco-605, and MDN-121. Coated and uncoated substrates were subjected to hot corrosion study under cyclic conditions. Each cycle consisted of 1 hour heating at 800°C followed by 20 minutes air cooling. Gravimetric measurements were done after each cycle and a plot of weight gain as a function of number of cycles is drawn. Parabolic rate constants were estimated for the understanding of corrosion behaviour. It was observed that coated Ti-31 and MDN-121 were more resistant compared to the uncoated ones. Uncoated superco-605 was undergoing sputtering during corrosion study and hence comparison between coated and uncoated superco-605 was difficult. The cross-sectional analysis of the corroded, coated samples indicated the presence of a thin layer of chromium oxide scale on the top of the coating and it imparted better corrosion resistance. Parabolic rate constants also indicated that coating is more beneficial to Ti-31 than to MDN-121. © 2013 N. Jegadeeswaran et al.Item Production of layer by layer Zn-Fe compositional multilayer alloy coatings using triangular current pulses for better corrosion protection(Maney Publishing, 2015) Bhat, R.S.; Hegde, A.Multiple-layer coatings of Zn-Fe alloy having alternatively the same compositions have been developed galvanostatically on mild steel (MS) from a single plating bath using triangular current pulses. Thiamine hydrochloride (THC) and citric acid (CA) were used as additives. Multiple-layer coatings were developed under different conditions of cyclic cathode current density (CCCD) and number of layers. Cyclic voltammetry demonstrated that the addition of THC and CA improves the deposit character by increasing the Ni content (through suppressing the deposition of Zn) via preferential adsorption on the cathode surface. The corrosion behaviours of the coatings were evaluated by electrochemical AC and DC methods. The optimum multiple-layer coating, represented as (Zn-Fe)3.0/5.0/300, was found to exhibit about four to five times better corrosion resistance when compared with monolayer (Zn-Fe)3.0 alloy, developed from the same bath for the same duration. Distinct phase structures responsible for interface formation between successive layers (which changes alternatively) were confirmed by X-ray diffraction analysis. Better corrosion resistance afforded by multiple-layer coating was attributed to the increased specific surface area of the coating because of layering. A synergistic effect of both structural difference between layers and individual layer thickness is responsible for enhanced corrosion resistance of the multiple-layer coatings. The formation of multiple layers and corrosion mechanism were analysed by scanning electron microscopy. © 2015 Institute of Materials Finishing.Item Plasma nitriding of AISI 2205 steel: Effects of surface mechanical attrition treatment and chemical etching(Maney Publishing michael.wagreich@univie.ac.at, 2016) Gatey, A.M.; Hosmani, S.S.; Arya, S.B.; Figueroa, C.A.; Singh, R.P.In the present study, surface mechanical attrition treatment (SMAT) and plasma nitriding were conducted on AISI 2205 steel. SMAT was effective in enhancing the surface hardness of the steel by about 80%. The influence of SMAT on the corrosion behaviour of the steel was studied in a 3.5 wt-% NaCl solution. Due to the stable and thicker passive layer, improved corrosion resistance was observed for the SMATed steel. However, nitrogen diffusion during plasma nitriding was impeded by the improved passivation, especially for the lower duration (30 min) of chemical etching/cleaning (i.e. sputter cleaning in hydrogen plasma) of the specimen's surface. Furthermore, high chemical etching duration (120 min) resulted in improved surface hardness and nitriding kinetics. © 2016 Institute of Materials, Minerals and Mining.Item Synthesis of effective electrocatalyst for water splitting application from simple Cu-Ni bath(Allerton Press Incorporation journals@allertonpress.com, 2017) Elias, L.; Banjan, R.U.; Hegde, A.C.Electrocatalytically active Cu-Ni alloy coatings have been developed from a simple electrolyte having only Cu+2 and Ni+2 ions, without the use of any additive. Electrocatalytic character of the coatings was tested for their hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) in 1.0 M KOH medium, alongside with their corrosion behaviours. Cyclic voltammetry and chronopotentio-metry study revealed that the deposition current density has a prominent role on the alkaline water splitting behaviour of the coatings, depending on their phase structure, composition and surface morphology. It was found that the c.d. has an inverse dependence on HER and OER. The Cu-Ni alloy coatings developed, respectively at 3.0 and 4.0 A dm–2, were found to be the best coatings for HER and OER, depending on the surface morphology. The electrocatalytic activity of Cu-Ni alloy coating for HER, deposited at 3.0 A dm–2 (optimal), was further improved through electrochemical dissolution of the as-deposited coating. The increase in the electrocatalytic activity for HER has been attributed to the enhancement in the exposed surface area of Ni active sites due to the leaching of Cu from the alloy matrices, evidenced by the energy-dispersive X-ray spectroscopy and scanning electron microscopy. The dependencies of HER and OER on to the surface of Cu-Ni alloy coatings were analysed in terms of deposition c.d. of the coatings, and the results are discussed. © 2017, Allerton Press, Inc.Item Corrosion protection of low-cost carbon steel with SS-309Mo and Inconel-625 bimetallic weld overlay(Institute of Physics Publishing helen.craven@iop.org, 2019) Mudha, A.A.; Shashikala, H.D.; Nagaraja, H.S.The dissimilar weld overlay coatings of components can lead to corrosion. In the present work, two different weld overlay layers (SS-309Mo and Inconel-625) are deposited on IS2062 grade B carbon steel, in order to avoid distortions and improve corrosion resistance. The microstructural investigations revealed that the intermediate layer SS-309Mo on carbon steel prevents the dilution by aiding crack-free weld overlay of Inconel-625 on the top. The corrosion behaviour of the coatings is studied using Linear Polarization Resistance and the Electrochemical Impedance Spectroscopy. The corrosion rate of the coatings decreased by two orders of magnitude compared to that of low carbon steel substrate. The corrosion rate of the deposited Inconel-625 along with intermediate SS-309Mo is 1.16×10-3 and is comparable to that of bare Inconel-625 (1.12×10-3 mmpy). Further, the immersion tests for 14 days show that, the depositions are stable with the formation of the passive film. ©2019 IOP Publishing Ltd.Item The corrosion behavior of AZ31 alloy in chloride and sulfate media – A comparative study through electrochemical investigations(National Engg. Reaserch Center for Magnesium Alloys zhangdingfei@cqu.edu.cn, 2019) Acharya, M.; Nityananda Shetty, A.N.The magnesium alloys are considered to be the best structural materials, because of their advantageous weight to strength ratio. But, the limitation in their real field applications lies on the fact that magnesium alloys are highly susceptible for corrosion. The corrosion behaviour of AZ31 alloy was investigated by electrochemical methods in sodium chloride and sodium sulphate of different concentrations at different temperatures. The corrosion rate was monitored by potentiodynamic polarization technique and electrochemical impedance spectroscopy method. The surface morphology and surface composition of the freshly polished surface of the alloy was compared with that of the corroded surface by recording their SEM images and EDS, respectively. The results showed that the corrosion rate of AZ31 alloy increased with the increase in the temperature of the medium and also with the increase in the salt concentration of the medium. The activation parameters for the corrosion process were calculated and interpreted. © 2019Item Analysing the combined effect of crystallographic orientation and grain refinement on mechanical properties and corrosion behaviour of ECAPed ZE41 Mg alloy(National Engg. Reaserch Center for Magnesium Alloys, 2020) Sekar, S.; Narendranath, S.; Desai, V.Two step equal channel angular pressing carried out on as cast ZE41 Mg alloy resulted in a remarkable grain refinement. As compared to grain size of 46 µm in as cast sample, refinement upto 2.5 µm was achieved after 8th pass equal channel angular pressing (ECAP). The combined effect of crystallographic orientation and grain refinement was investigated by analysing the mechanical properties and corrosion behaviour of ZE41 Mg alloy using electron back scattered diffraction (EBSD). The first stage comprises of 1st, 2nd, 3rd and 4th passes at a processing temperature of 300 °C while the 5th, 6th, 7th and 8th passes were ECAPed at 275 °C in second stage. The mechanical properties of ZE41 Mg 158 yield tensile strength (YTS), 230 ultimate tensile strength (UTS) and 7% elongation in as cast condition is enhanced to 236 YTS, 295 UTS and 19.76%, respectively, after first stage ECAP. The yield tensile strength deteriorated due to the effect of texture predominating grain refinement during the second stage ECAP. The corrosion resistance of ZE41 Mg was significantly enhanced by ECAP and is inferred from electrochemical impedance spectroscopy (EIS) and potentiodynamic polarisation results .The role of microstructure was minimal on corrosion behaviour of ZE41 Mg due to extra resistance when tested in 0 M NaCl. However, the influence of grain refinement greatly influenced the improvement in corrosion resistance of ZE41 Mg rather than crystallographic orientation observed from EBSD. In contrast, the crystallographic orientation predominated the effect of grain refinement during ZE41 Mg corrosion in chloride containing (0.1 M and 1 M NaCl) solutions. From the observation of results it is found that equal channel angular pressing has the dual advantage of improving mechanical properties and corrosion resistance of ZE41 Mg alloy. © 2020Item Effect of Potassium Sodium Tartrate on Composition and Corrosion Performance of Ni–W Alloy Coatings(Pleiades journals, 2021) Neethu Raveendran, M.; Hegde, A.C.Abstract: In this communication, the effect of potassium sodium tartrate as complexing agent on the composition, phase structure, surface morphology, and corrosion performance of electrodeposited nickel-tungsten alloy coatings is reported. The deposition conditions were optimized for the best performance of the coatings against corrosion. Ni–W coatings were developed at different current densities and their corrosion behaviour was studied. Compositional data revealed that the noble metal tungsten content of the alloy decreased with growing cathodic current densities. Characteristics responsible for the best anticorrosion performance of Ni–W alloy coatings were compared with those of a citrate bath, earlier reported by the authors and their colleagues. The experimental study in this paper demonstrated an inverse dependency of the W content of Ni–W alloy on a current density, compared to that in a citrate bath. The X-ray diffraction study revealed that anticorrosion performance is driven by the W content of the alloys, not by the current density at which they are deposited. An inverse dependency of the W content on a current density, is discussed in the light of the theory of the mass transfer controlled M-complex ions (where M = W/Ni), associated in the deposition. It is supposed that a decrease/an increase of the W content in a tartrate or a citrate bath with the current density is afforded by a lower limiting current density (iL) of the W/Ni-complex ion, depending on the stability of the M-tartrate/citrate complex formed. The experimental results were discussed with the help of different analytical techniques, like scanning electron microscopy, energy dispersive spectroscopy, and X-ray diffractometry. © 2021, Allerton Press, Inc.