In a significant stride towards enhancing the durability and performance of industrial coatings, researchers have uncovered the pivotal role of inter-splat adhesion in High-Velocity Oxygen Fuel (HVOF)-sprayed 434 stainless steel coatings on T6061 aluminum alloy substrates. This breakthrough, published in the Journal of Materials Research and Technology, could have profound implications for the energy sector, particularly in applications requiring robust corrosion and wear resistance.
Led by Yaming Li from the State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals at Lanzhou University of Technology, the study delves into the intricate world of coating technologies. The research team applied 434 stainless steel coatings to T6061 aluminum substrates using HVOF spraying, varying the spray parameters to investigate their impact on inter-splat adhesion and overall coating properties.
The findings are compelling. “For thicker coatings containing more layers, the deposition temperature was higher, the coating porosity was lower, and the adhesion between splats was stronger, presenting better properties,” Li explained. The optimal coating sample, dubbed SS1-3, exhibited a maximum bonding strength of 52.9 MPa and a wear rate of just 5.94 × 10−5 mm3/(N·m), half that of the SS 2-2 sample. This remarkable performance is attributed to localized metallurgical bonding at the splat interface.
Moreover, the coated samples demonstrated superior corrosion resistance compared to pure T6061 aluminum, with the corrosion current density reduced from 18.6 μA/cm2 to 3.5 μA/cm2. The study also established mechanisms for coating failure, shedding light on the effects of inter-splat adhesion under tension and wear.
The implications for the energy sector are substantial. In environments where equipment is exposed to harsh conditions, such as offshore wind turbines or oil and gas installations, the enhanced durability and performance of these coatings could lead to significant cost savings and improved safety. “This research opens up new avenues for developing high-performance coatings that can withstand extreme conditions,” Li noted.
As the energy sector continues to evolve, the demand for materials that can endure harsh environments while maintaining optimal performance is growing. This research not only advances our understanding of coating technologies but also paves the way for future innovations in the field. With the findings published in the Journal of Materials Research and Technology, the scientific community now has a robust foundation to build upon, potentially revolutionizing industrial coating applications in the energy sector.