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<p>The present study investigates the effect of graphene nanoplatelets (GNPs) on the microstructure and corrosion resistance of WC-CoCr coatings deposited via high-velocity air fuel (HVAF) spraying. The HVAF process effectively mitigated decarburization through its controlled lower combustion temperature. The addition of 1 wt.% and 2 wt.% GNPs markedly improved coating densification by filling nanoscale pores, thereby reducing porosity and achieving a relative density of 99.57% for WC-CoCr + 2G. The high thermal conductivity of GNPs enabled uniform heat dissipation during spraying, leading to a 9.7% reduction in crystallite size, and a 25.6% decrease in lattice strain. Electrochemical studies in 3.5 wt.% NaCl solution revealed a remarkable reduction in the corrosion rate, dropping from 4.27 × 10<sup>–6</sup>&#xa0;mpy for WC-CoCr to 1.71 × 10<sup>–8</sup> mpy for WC-CoCr + 2G, demonstrating an almost 99% improvement. The enhanced corrosion resistance is attributed to GNPs acting as a diffusion barrier against Cl<sup>−</sup> and Na<sup>+</sup> ions while simultaneously catalyzing the rapid formation of a protective Cr<sub>2</sub>O<sub>3</sub> passivation layer. This novel insight into the functional role of GNPs in tuning microstructure, strain relaxation, and electrochemical stability establishes HVAF-sprayed GNP-reinforced WC-CoCr coatings as a transformative solution for high-performance corrosion protection in aggressive environments.</p>

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Graphene-Reinforced WC-CoCr Coatings by High-Velocity Air Fuel Spraying: A Path to Superior Corrosion Protection

  • 期刊论文

  • 发表日期：

    2025年7月10日

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  • Ishee Prasad Kar,
  • Santosh Kumar,
  • Navneet K. Singh,
  • Swati Sharma,
  • Shailesh Mani Pandey,
  • Anup Kumar Keshri

摘要

The present study investigates the effect of graphene nanoplatelets (GNPs) on the microstructure and corrosion resistance of WC-CoCr coatings deposited via high-velocity air fuel (HVAF) spraying. The HVAF process effectively mitigated decarburization through its controlled lower combustion temperature. The addition of 1 wt.% and 2 wt.% GNPs markedly improved coating densification by filling nanoscale pores, thereby reducing porosity and achieving a relative density of 99.57% for WC-CoCr + 2G. The high thermal conductivity of GNPs enabled uniform heat dissipation during spraying, leading to a 9.7% reduction in crystallite size, and a 25.6% decrease in lattice strain. Electrochemical studies in 3.5 wt.% NaCl solution revealed a remarkable reduction in the corrosion rate, dropping from 4.27 × 10–6 mpy for WC-CoCr to 1.71 × 10–8 mpy for WC-CoCr + 2G, demonstrating an almost 99% improvement. The enhanced corrosion resistance is attributed to GNPs acting as a diffusion barrier against Cl− and Na+ ions while simultaneously catalyzing the rapid formation of a protective Cr2O3 passivation layer. This novel insight into the functional role of GNPs in tuning microstructure, strain relaxation, and electrochemical stability establishes HVAF-sprayed GNP-reinforced WC-CoCr coatings as a transformative solution for high-performance corrosion protection in aggressive environments.