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<p>Cerium oxide (CeO<sub>2</sub>) is well known for its chemical stability, low toxicity, and corrosion resistance, making it a promising material for protective surface coatings. In this study, composite coatings of CeO<sub>2</sub> and graphene nanoplatelets (GNPs) were deposited using air plasma spraying (APS) and subsequently enhanced via spark plasma sintering (SPS). Structural and electrochemical characterizations were carried out using field emission scanning electron microscopy (FE-SEM), x-ray diffraction (XRD), and electrochemical techniques in phosphate-buffered saline (PBS) solution. The SPS process significantly reduced coating porosity and sealed interlamellar cracks, resulting in improved microstructural cohesion. Electrochemical evaluations revealed that the SPS-treated coatings exhibited a corrosion current density approximately 82% lower, and a corrosion potential nearly nine times more positive than that of the as-sprayed samples—indicating substantial enhancement in corrosion resistance. In addition, electrochemical impedance spectroscopy (EIS) data were modeled using an equivalent electrical circuit, confirming increased coating resistance and reduced interfacial capacitance. This work demonstrates the novel application of SPS as an effective post-treatment for microstructural and electrochemical optimization of thermally sprayed CeO<sub>2</sub>-based composite coatings.</p>

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Effect of Spark Plasma Sintering on the Corrosion Resistance of Thermally Sprayed CeO2/Graphene Nanocomposites

  • 期刊论文

  • 发表日期：

    2026年5月1日

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  • Ali Jounaki,
  • Seyedeh Zahra Anvari,
  • Mohammad Reza Toroghinejad

摘要

Cerium oxide (CeO2) is well known for its chemical stability, low toxicity, and corrosion resistance, making it a promising material for protective surface coatings. In this study, composite coatings of CeO2 and graphene nanoplatelets (GNPs) were deposited using air plasma spraying (APS) and subsequently enhanced via spark plasma sintering (SPS). Structural and electrochemical characterizations were carried out using field emission scanning electron microscopy (FE-SEM), x-ray diffraction (XRD), and electrochemical techniques in phosphate-buffered saline (PBS) solution. The SPS process significantly reduced coating porosity and sealed interlamellar cracks, resulting in improved microstructural cohesion. Electrochemical evaluations revealed that the SPS-treated coatings exhibited a corrosion current density approximately 82% lower, and a corrosion potential nearly nine times more positive than that of the as-sprayed samples—indicating substantial enhancement in corrosion resistance. In addition, electrochemical impedance spectroscopy (EIS) data were modeled using an equivalent electrical circuit, confirming increased coating resistance and reduced interfacial capacitance. This work demonstrates the novel application of SPS as an effective post-treatment for microstructural and electrochemical optimization of thermally sprayed CeO2-based composite coatings.