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<p>Corrosion induced failure remains a major challenge across various industries. Thermal spray coatings have proven to be a cost-effective and efficient solution to mitigate this issue. In this study, the corrosion behaviour of hybrid Al<sub>2</sub>O<sub>3</sub>–h-BN–La<sub>2</sub>O<sub>3</sub> coatings deposited using the High-Velocity Oxygen Fuel (HVOF) spraying process was investigated. The coatings consist of Al<sub>2</sub>O<sub>3</sub> reinforced with a fixed 3&#xa0;wt.% h-BN and varying weight percentages of La<sub>2</sub>O<sub>3</sub> (1.2%, 1.6%, and 1.8%). Surface wettability tests revealed a transition from hydrophilic to hydrophobic behaviour with increasing La<sub>2</sub>O<sub>3</sub> content. Notably, the coating S3 (95.4%Al<sub>2</sub>O<sub>3</sub>-3%h-BN-1.6%La<sub>2</sub>O<sub>3</sub>) exhibited significantly enhanced corrosion resistance, with polarization resistance about 100 times greater and corrosion rate nearly 400 times lower than the unreinforced La<sub>2</sub>O<sub>3</sub>coating. Electrochemical Impedance Spectroscopy (EIS) and Equivalent Electric Circuit (EEC) analysis confirmed superior barrier properties for the S3 coating, shown by its highest charge transfer resistance. Microstructural and phase analyses conducted via x-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) depicts the corrosion degradation mechanisms and phase transformations. These results demonstrate the synergistic effect of h-BN and La<sub>2</sub>O<sub>3</sub> reinforcement in improving the corrosion resistance and surface properties of Al<sub>2</sub>O<sub>3</sub>based coatings, indicating strong potential for enhanced durability in corrosive environments.</p>

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Influence of h-BN and La2O3 Reinforcement on the Corrosion Behaviour of Al2O3 HVOF Coatings

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Khushneet Singh,
  • Mir Irfan Ul Haq,
  • Sanjay Mohan,
  • Avi Gupta,
  • Deepak Kumar,
  • Mohd FarooqWani

摘要

Corrosion induced failure remains a major challenge across various industries. Thermal spray coatings have proven to be a cost-effective and efficient solution to mitigate this issue. In this study, the corrosion behaviour of hybrid Al2O3–h-BN–La2O3 coatings deposited using the High-Velocity Oxygen Fuel (HVOF) spraying process was investigated. The coatings consist of Al2O3 reinforced with a fixed 3 wt.% h-BN and varying weight percentages of La2O3 (1.2%, 1.6%, and 1.8%). Surface wettability tests revealed a transition from hydrophilic to hydrophobic behaviour with increasing La2O3 content. Notably, the coating S3 (95.4%Al2O3-3%h-BN-1.6%La2O3) exhibited significantly enhanced corrosion resistance, with polarization resistance about 100 times greater and corrosion rate nearly 400 times lower than the unreinforced La2O3coating. Electrochemical Impedance Spectroscopy (EIS) and Equivalent Electric Circuit (EEC) analysis confirmed superior barrier properties for the S3 coating, shown by its highest charge transfer resistance. Microstructural and phase analyses conducted via x-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) depicts the corrosion degradation mechanisms and phase transformations. These results demonstrate the synergistic effect of h-BN and La2O3 reinforcement in improving the corrosion resistance and surface properties of Al2O3based coatings, indicating strong potential for enhanced durability in corrosive environments.