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<p>This study presents an innovative approach to enhance the corrosion resistance of SS 304 stainless steel by employing high-velocity oxygen fuel (HVOF)-sprayed WC-10%Co-4%Cr (WCCr) coatings. The research systematically evaluates the electrochemical performance of these coatings in a simulated marine environment (3.5 wt.% NaCl), using advanced techniques such as potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), X-ray diffraction (XRD), and field emission scanning electron microscopy coupled with EDS. The coated specimens exhibited significantly improved electrochemical stability, evidenced by a pronounced decrease in corrosion current density from 4.95 × 10<sup>–5</sup> A/cm<sup>2</sup> to 4.68 × 10<sup>–6</sup> A/cm<sup>2</sup> and a positive shift in corrosion potential from –0.552&#xa0;V to -0.418&#xa0;V. EIS analysis demonstrated enhanced charge transfer resistance and capacitive behavior, confirming the superior barrier functionality of the coating. Microstructural evaluations revealed a dense, uniform coating with minimal porosity and strong coating-substrate adhesion. Post-corrosion analysis indicated minor binder leaching and grain refinement, yet the structural integrity remained intact. Crystallinity decreased from 94 to 88%, and crystallite size reduced from 24 to 16&#xa0;nm after corrosion exposure. These findings underscore the effectiveness of HVOF-sprayed WCCr coatings as a robust corrosion mitigation strategy for SS 304 in chloride-rich environments, offering improved mechanical durability and long-term performance. The study bridges the gap between microstructural optimization and corrosion resistance, providing a comprehensive framework for the design of high-performance protective coatings in aggressive service conditions.</p>

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Improving the Corrosion Performance of SS 304 Stainless Steel Using HVOF-Sprayed WC-Co-Cr Coatings in Chloride Environments

  • 期刊论文

  • 发表日期：

    2025年8月1日

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  • Praveen Kumar Verma,
  • Hitesh Vasudev,
  • Gurbhej Singh

摘要

This study presents an innovative approach to enhance the corrosion resistance of SS 304 stainless steel by employing high-velocity oxygen fuel (HVOF)-sprayed WC-10%Co-4%Cr (WCCr) coatings. The research systematically evaluates the electrochemical performance of these coatings in a simulated marine environment (3.5 wt.% NaCl), using advanced techniques such as potentiodynamic polarization, electrochemical impedance spectroscopy (EIS), X-ray diffraction (XRD), and field emission scanning electron microscopy coupled with EDS. The coated specimens exhibited significantly improved electrochemical stability, evidenced by a pronounced decrease in corrosion current density from 4.95 × 10–5 A/cm2 to 4.68 × 10–6 A/cm2 and a positive shift in corrosion potential from –0.552 V to -0.418 V. EIS analysis demonstrated enhanced charge transfer resistance and capacitive behavior, confirming the superior barrier functionality of the coating. Microstructural evaluations revealed a dense, uniform coating with minimal porosity and strong coating-substrate adhesion. Post-corrosion analysis indicated minor binder leaching and grain refinement, yet the structural integrity remained intact. Crystallinity decreased from 94 to 88%, and crystallite size reduced from 24 to 16 nm after corrosion exposure. These findings underscore the effectiveness of HVOF-sprayed WCCr coatings as a robust corrosion mitigation strategy for SS 304 in chloride-rich environments, offering improved mechanical durability and long-term performance. The study bridges the gap between microstructural optimization and corrosion resistance, providing a comprehensive framework for the design of high-performance protective coatings in aggressive service conditions.