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<p>The petroleum and petrochemical industries operate in highly aggressive environments where corrosion can severely compromise the integrity of critical equipment. This work investigates how key high-velocity oxygen fuel (HVOF) spraying factors influence the coating integrity and corrosion performance of tungsten carbide layers deposited on AISI 4130 steel. The powder feed rate (ranging from 60 to 80 g/min) and spray pressure (ranging from 6.5 to 7.4 bar) were systematically varied for samples C1-C5, while an uncoated specimen served as the control. Microstructural characterization using scanning electron microscopy confirmed variations in coating density and thickness across the samples. Mechanical performance was evaluated through Vickers hardness measurements, indicating a significant increase (from 225 HV for the uncoated steel to 2060 HV and 2020 HV for samples C3 and C5, respectively). Corrosion performance was examined using Tafel polarization testing and EIS (electrochemical impedance spectroscopy). The HVOF-processed coatings significantly enhanced corrosion resistance compared with the bare substrate, with sample C3 demonstrating the lowest corrosion current density and a more noble corrosion potential. Nyquist analysis further indicated that C3 possessed the highest charge-transfer resistance due to its uniform WC distribution and reduced porosity. Overall, the optimal performance was achieved using a spray pressure of 7.2 bar and a powder feed rate of 72 g/min, identifying sample C3 as the most effective configuration for corrosion protection.</p> Graphical Abstract <p></p>

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Microstructural Characterization and Corrosion Performance of HVOF-Sprayed WC-Based Coatings on AISI 4130 Steel Substrates

  • 期刊论文

  • 发表日期：

    2026年5月3日

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  • Sirus Safaee,
  • Amirhossein Moghanian,
  • Shigeaki Abe,
  • Mohammad Abedini Mohammadi,
  • Mahdis Nesabi,
  • Niloufar Kolivand,
  • Morteza Saghafi Yazdi,
  • Ikuya Watanabe,
  • Hiroshi Murata

摘要

The petroleum and petrochemical industries operate in highly aggressive environments where corrosion can severely compromise the integrity of critical equipment. This work investigates how key high-velocity oxygen fuel (HVOF) spraying factors influence the coating integrity and corrosion performance of tungsten carbide layers deposited on AISI 4130 steel. The powder feed rate (ranging from 60 to 80 g/min) and spray pressure (ranging from 6.5 to 7.4 bar) were systematically varied for samples C1-C5, while an uncoated specimen served as the control. Microstructural characterization using scanning electron microscopy confirmed variations in coating density and thickness across the samples. Mechanical performance was evaluated through Vickers hardness measurements, indicating a significant increase (from 225 HV for the uncoated steel to 2060 HV and 2020 HV for samples C3 and C5, respectively). Corrosion performance was examined using Tafel polarization testing and EIS (electrochemical impedance spectroscopy). The HVOF-processed coatings significantly enhanced corrosion resistance compared with the bare substrate, with sample C3 demonstrating the lowest corrosion current density and a more noble corrosion potential. Nyquist analysis further indicated that C3 possessed the highest charge-transfer resistance due to its uniform WC distribution and reduced porosity. Overall, the optimal performance was achieved using a spray pressure of 7.2 bar and a powder feed rate of 72 g/min, identifying sample C3 as the most effective configuration for corrosion protection.

Graphical Abstract