Comparative Study of Corrosion Performance of HVOF-Sprayed Coatings Produced Using Conventional and Suspension WC-Co Feedstock

Corrosion properties of nanostructured coatings deposited by suspension high-velocity oxy-fuel (S-HVOF) via an aqueous suspension of milled WC-Co powder were compared with conventional HVOF-sprayed coatings. Microstructural evaluations of these coatings included x-ray diffraction and scanning electron microscopy equipped with an energy-dispersive x-ray spectroscopy. The corrosion performance of AISI440C stainless steel substrate and the coatings was evaluated in a 3.5 wt.% NaCl aqueous solution at ~ 25 °C. The electrochemical properties of the samples were assessed experimentally, employing potentiodynamic polarization and electrochemical impedance spectroscopy. The potentiodynamic polarization results indicated that coatings produced by S-HVOF technique show lower corrosion resistance compared with the coatings produced by HVOF-JK (HVOF Jet Kote) and HVOF-JP (HVOF JP5000) techniques. Results are discussed in terms of corrosion mechanism, Bode and Nyquist plots, as well as equivalent circuit models of the coating–substrate system.