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Title: Effect of chlorides on the electrochemical behaviour of thermally sprayed aluminium protective coatings
Author: Rios, Giancarlo
ISNI:       0000 0004 2733 7359
Awarding Body: University of Manchester
Current Institution: University of Manchester
Date of Award: 2012
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Sacrificial metallic coatings have been used in the past, for protecting steel in industrial and urban developments. It has been suggested that thermally sprayed aluminium coatings, immersed in marine environments, are also capable of protecting steel by providing galvanic protection. Researchers have also speculated that the growth of inert oxide products, on top of the coating as well as inside pores and cracks, could enhance even further its protective “shielding” properties. In addition, the self-healing abilities of the coatings, in case of mechanically induce damage, are still a matter of debate. This research project takes a critical look at these assumptions, focusing on the electrochemical response of aluminium metal sprayed (AMS) coatings immersed in 0.6 M NaCl and 0.6 M Na2SO4 solutions, in order to investigate how the presence of chlorides can alter the corrosion behaviour of these coatings. For such, a thin aluminium protective coating was deposited over two different panels (aluminium 1050 and low carbon steel), by the steel making company Fairfield-Mabey, using electric arc thermal spraying (TS). Subsequently, the coated panels were sectioned into smaller specimens, and with the aid of a SEM/EDS, and XRD, observations and analysis were conducted in their surfaces and cross sections, in order to determine the morphology, quality of deposition, and chemical composition of the coatings. Internal porosity/oxide growth after immersion, was studied using 3-D X-ray tomography scanning. Furthermore, the electrochemical behaviour of the coatings (intact and scribed) was also investigated, initially by analyzing the evolution of the open circuit potential in time, when immersed in chloride rich and chloride free environments. Additionally, the anodic polarization behaviour of the substrate and coatings were simultaneously analyzed, by connecting a zero resistance ammeter (ZRA) with the W.E. terminal of a potentiostat. To conclude, EIS and Rp vs. time plots were made in order to corroborate the data obtained from other tests. Results show that although the coating can generate superficial and internal corrosion products, these oxides are not isolating in nature nor will enhance its protective properties. On the other hand, the corrosion potential behaviour of the coatings revealed that AMS coatings have a more active than the substrate; regardless of the environment in which they were immersed or their substrate. Nevertheless, it was also observed that AMS coatings deposited onto steel will corrode faster than their substrates, and for that matter capable of offering corrosion protection, exclusively if chlorides are present in the solution.
Supervisor: Lyon, Stuart Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available
Keywords: Corrosion ; Aluminium ; Steel ; Protective Coatings ; Anodic Polarization ; Thermal Spraying ; AMS ; X-ray tomography