Faculty Publications
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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 High temperature corrosion behaviour of HVOF sprayed WC-CrC-Ni coatings(Inderscience Publishers, 2016) Somasundaram, B.; Kadoli, R.; Ramesh, M.R.; RAMESH, C.S.The present work aims to study the hot corrosion resistance of high velocity oxy-fuel (HVOF) sprayed WC-CrC-Ni coating developed on three types of boiler tube materials such as SA213-T22, MDN-310 and Superfer 800 H steels. Hot corrosion studies were conducted in a molten salt environment of Na2SO4-60%V2O5 at 700°C and thermogravimetric analysis was used to establish kinetics of corrosion. Corrosion kinetics of coated steels followed nearly parabolic behaviour and showed a lower corrosion rate in comparison to uncoated alloys. It is concluded that corrosion is restricted to the external surface of the coating and the formation of thick scale composed of oxides of Cr, Ni and their spinel oxides, acts as a diffusion barrier to the transportation of corrosive species into the coating. The carbides of tungsten and chromium uphold the strength of the coating. © © 2016 Inderscience Enterprises Ltd.Item Development of multilayer Sn-Ni alloy coating by pulsed sonoelectrolysis for enhanced corrosion protection(Royal Society of Chemistry, 2016) Shetty, S.; Mohamed, M.J.; Bhat, D.; Hegde, A.C.Multilayer Sn-Ni alloy coating has been developed electrochemically on mild steel using an ultrasound effect, as a tool to modulate mass transfer process at electrical double layer, during deposition. Sn-Ni coatings having alternate layers of alloys of different compositions were developed on a nano/micrometric scale by pulsing sonicator ON (tON) and OFF (tOFF), periodically. The composition modulated multilayer alloy (CMMA) Sn-Ni coatings have been deposited by inducing the ultrasound field periodically at optimal current density. Corrosion performances of ultrasound-assisted multilayer Sn-Ni alloy coatings have been evaluated by electrochemical methods. Corrosion data revealed that CMMA Sn-Ni coating, developed using pulsed ultrasonic field and having 150 layers, represented as (Sn-Ni)2/2/150, is the most corrosion resistant, compared to its monolayer alloy coatings developed by both with/without ultrasound effect. Corrosion protection efficacy of multilayer coatings was found to be decreased at high degree of layering due to diffusion of layers. Improved corrosion resistance of multilayer Sn-Ni coatings is attributed to an increase in the number of layers, or interfaces separating alloys of the same metals, but of different composition, surface morphologies and phase structures, supported by energy dispersive spectroscopy, field emission scanning electron microscopy and X-ray diffraction study, respectively. The better corrosion protection of CMMA Sn-Ni coatings, compared to monolayer counterparts, is attributed to an increase in the number of layers, hence phase boundaries between layers, and experimental results are discussed. © 2018 The Royal Society of Chemistry.Item Ultrasound induced multilayer Ni-Co alloy coatings for better corrosion protection(Elsevier B.V., 2017) Shetty, A.R.; Hegde, A.Ultrasound induced multilayer Ni-Co alloy coatings have been developed galvanostatically by periodic modulation of ultrasound effect, parallel to the process of conventional electroplating. Multilayer Ni-Co alloy having alternative layers of different composition were developed by turning the sonicator probe, ON and OFF periodically, while keeping the current density (c.d.) constant. The deposition conditions, in terms of pulsing power density (p.d.) and degree of layering have been optimized for the highest performance of coating against corrosion, evaluated by electrochemical testing methods. Corrosion data revealed that under optimal conditions, multilayer Ni-Co alloy coating having 150 layers, represented as (Ni-Co)2/2/150 is about 11 times more corrosion resistant than its homogeneous coating, represented as (Ni-Co)4.0 A dm ? 2, deposited from the same bath for same duration of time. Improved corrosion resistance of multilayer Ni-Co alloy coatings was attributed to an increase in the number of interfaces, separating the layers of alloys of different composition, affected due to periodic pulsing of the sonicator. The dependence of corrosion behaviors at different combination of c.d. and p.d., on surface morphology, composition and phase structures were analyzed, using scanning electron microscopy (SEM), energy dispersion spectroscopy (EDS) and X-ray diffraction (XRD) technique, respectively. Experimental results are compared, and discussed. © 2017 Elsevier B.V.Item Corrosion resistance and in-vitro bioactivity of BaO containing Na2O-CaO-P2O5 phosphate glass-ceramic coating prepared on 316 L, duplex stainless steel 2205 and Ti6Al4V(Institute of Physics Publishing helen.craven@iop.org, 2018) Edathazhe, A.B.; Shashikala, H.D.The phosphate glass with composition 11Na2O-15BaO-29CaO-45P2O5 was coated on biomedical implant materials such as stainless steel 316 L, duplex stainless steel (DSS) 2205 and Ti6Al4V alloy by thermal enamelling method. The structural properties and composition of glass coated substrates were studied by x-ray diffraction (XRD), Scanning electron microscopy (SEM) and Energy dispersive x-ray spectroscopy (EDS) analysis. The coatings were partially crystalline in nature with porous structure and pore size varied from micro to nanometer range. The polarization curve was obtained for uncoated and coated substrates from electrochemical corrosion test which was conducted at 37 °C in Hank's balanced salt solution (HBSS). The corrosion resistance of 316 L substrate increased after coating, whereas it decreased in case of DSS 2205 and Ti6Al4V. The XRD and SEM/EDS studies indicated the bioactive hydroxyapatite (HAp) layer formation on all the coated surfaces after electrochemical corrosion test, which improved the corrosion resistance. The observed electrochemical corrosion behavior can be explained based on protective HAp layer formation, composition and diffusion of ions on glass coated surfaces. The in-vitro bioactivity test was carried out at 37 °C in HBS solution for 14 days under static conditions for uncoated and coated substrates. pH and ion release rate measurements from the coated samples were conducted to substantiate the electrochemical corrosion test. The lower ion release rates of Na+ and Ca2+ from coated 316 L supported its higher electrochemical corrosion resistance among coated samples. Among the uncoated substrates, DSS showed higher electrochemical corrosion resistance. Amorphous calcium-phosphate (ACP) layer formation on all the coated substrates after in-vitro bioactivity test was confirmed by XRD, SEM/EDS and ion release measurements. The present work is a comparative study of corrosion resistance and bioactivity of glass coated and uncoated biomedical implants such as 316 L, DSS and Ti6Al4V. © 2018 IOP Publishing Ltd.Item Cyclic Oxidation and Hot Corrosion Behavior of Plasma-Sprayed CoCrAlY + WC-Co Coating on Turbine Alloys(Springer New York LLC barbara.b.bertram@gsk.com, 2018) Nithin, H.S.; Vijay, D.; Ramesh, M.R.Components in energy-producing systems suffer a variety of degradation processes such as oxidation and molten salt-induced corrosion as a consequence of complex multi-component gaseous environment. Coatings provide a composition that will grow the protective scale at high temperatures having long-term stability. Plasma spraying was used to deposit CoCrAlY + WC-Co composite coatings on turbine alloys of Hastelloy X and AISI 321. The thermocyclic oxidation behavior of coated alloys was investigated in static air and in molten salt (Na2SO4-60%V2O5) environment at 700 °C. The thermogravimetric technique was used to approximate the kinetics of oxidation in 50 cycles, each cycle consisting of heating and cooling. X-ray diffraction and SEM/EDAX techniques are used to characterize the oxide scale formed. Coated alloys showed a lower corrosion rate as compared to uncoated alloys. The coatings subjected to oxidation and hot corrosion showed slow scale growth kinetics. Preferential oxidation of Co, Cr, W and its spinel blocks the transport of oxygen and corrosive species into the coating by providing a barrier, thereby making the oxidation rate to reach steady state. As compared to the substrate alloys, coatings show better hot corrosion resistance. © 2018, ASM International.Item Hot corrosion resistance of air plasma sprayed ceramic Sm2SrAl2O7 (SSA) thermal barrier coatings in simulated gas turbine environments(Elsevier Ltd, 2018) Baskaran, T.; Arya, S.Samarium strontium aluminate (Sm2SrAl2O7-SSA) and Yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBCs) were developed on NiCrAlY bond coated Inconel 718 superalloy substrate using air plasma spray process. The hot corrosion study was conducted in simulated gas turbine environments (molten mixtures of 50 wt% Na2SO4 + 50 wt% V2O5 and 90 wt% Na2SO4 + 5 wt% V2O5 + 5 wt% NaCl) for two different temperatures of 700 and 900 °C. A developed SSA TBCs showed about 8% and 22% lower lifetime at 700 and 900 °C, respectively than YSZ TBCs in 50 wt% Na2SO4 + 50 wt% V2O5 (vanadate). The hot corrosion life of SSA TBCs being found about 13% and 39% lower than YSZ TBCs in 90 wt% Na2SO4 + 5 wt% V2O5 + 5 wt% NaCl (chloride) at 700 and 900 °C, respectively. X-ray diffraction results showed the formation of SmVO4, SrV2O6, and SrSO4 as a major hot corrosion product in 50 wt% Na2SO4 + 50 wt% V2O5 and 90 wt% Na2SO4 + 5 wt% V2O5 + 5 wt% NaCl environments respectively for SSA TBCs. Similarly, YSZ TBCs also showed YVO4 as hot corrosion product in vanadate and chloride environments. Both the TBCs suffer a more severe hot corrosion attack in chloride environment at 900 °C. The leaching of Sr2+ and Y3+ ions from SSA and YSZ respectively play a vital role in the destabilization of coating in vanadate and chloride environments at 700 and 900 °C. In both SSA and YSZ TBCs, the leaching of ion has significantly low influence as compared to attack by chloride ions at the bond coat-top coat interface in the presence of chloride environment. The hot corrosion resistance of SSA TBCs was improved three times higher in the presence of MgO and NiO inhibitor in vanadate environment at 900 °C mainly due to the formation of a stable Ni3V2O8 phase at the surface. © 2018 Elsevier Ltd and Techna Group S.r.l.Item Crosslinked polymer doped binary coatings for corrosion protection(Elsevier B.V., 2018) Kaur, H.; Sharma, J.; Jindal, D.; Arya, R.K.; Ahuja, S.K.; Arya, S.Solvent-based polymeric multilayer coatings prepared by ex-situ addition of crosslinked poly(styrene-co-divinyl benzene) in poly(styrene)-ethylbenzene solution were examined for corrosion protection of mild steel in a simulated water environment equivalent to sea water and acid rain. Electrochemical impedance spectroscopy (EIS) technique was used to determine the corrosion resistance behavior of the prepared polymeric coatings in 3.5 wt % of NaCl aqueous solution. EIS analysis suggested that the sample solution prepared by adding 1% crosslinked polymer in poly(styrene)-ethylbenzene solution, has better corrosion resistance as compared to the sample solutions prepared by adding 3% and 2% of crosslinked polymer in poly(styrene)-ethylbenzene solutions. Scanning electron microscopy (SEM) revealed that substrate coated with polymeric solution prepared by adding 1% of crosslinked polymer in poly(styrene)-ethyl benzene solution showed less corrosion as compared to the substrates coated with sample solutions prepared by adding 3% and 2% of crosslinked polymer in poly(styrene)-ethylbenzene solutions. © 2018 Elsevier B.V.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 Hot corrosion behaviour of HVOF sprayed Ni3Ti and Ni3Ti + (Cr3C2 + 20NiCr) coatings in presence of Na2SO4-40%V2O5 at 650 °c(IOP Publishing Ltd custserv@iop.org, 2019) Reddy, N.C.; Koppad, P.G.; Reddappa, H.N.; Ramesh, M.R.; Babu, E.R.; Varol, T.Ni3Ti and Ni3Ti + (Cr3C2 + 20NiCr) coatings were deposited on gas turbine based ASTM B265 titanium (Ti-15) and AISI 420 stainless steel (MDN-420) substrate materials using HVOF technique. Thermocyclic hot corrosion tests were carried out at 650 °C in molten salt environment of Na2SO4-40%V2O5 for about 50 cycles. Thermogravimetric analysis was carried out to study the hot corrosion kinetics of uncoated and coated titanium and stainless steel substrates. The weight gain per unit area showed that the coated substrate materials displayed better resistance to hot corrosion when compared with that of uncoated substrate materials. The surface morphology of uncoated and coated substrate materials were analysed using scanning electron microscopy and elemental analysis. The formation of different types of oxides and compounds were analysed using x-ray diffraction. The uncoated substrates surface showed microspalling at several regions while coated substrates surface were composed of protective oxide layers. The presence of ternary NiCr2O4 protective oxides on the surface of Ni3Ti + (Cr3C2 + 20NiCr) coated substrates leads to reduction in the diffusion of corrosive species inside the coating. © 2019 IOP Publishing Ltd.