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Title: Corrosion Performance of Wire Arc Deposited Zinc Aluminum Pseudo Alloy and Zinc 15 Aluminum Alloy Coatings on Steel in Chloride Environment
Award ID(s):
1750316
PAR ID:
10406440
Author(s) / Creator(s):
; ;
Date Published:
Journal Name:
Journal of Thermal Spray Technology
Volume:
31
Issue:
6
ISSN:
1059-9630
Page Range / eLocation ID:
1918 to 1933
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
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  1. This study examined the influence of laboratory corrosion testing methods, specifically salt spray, and immersion tests, on the long-term performance assessment of wire-arc-sprayed Zn-Al coatings. Two Zn-Al alloyed systems, Zn-15Al and Zn-Al pseudo-alloy, were selected for investigation, subjecting them to 1000 h of immersion and salt spray conditions. Electrochemical impedance spectroscopy was used to monitor corrosion progression in both coating systems at 200-h intervals. Post-exposure, the coatings underwent microstructural and chemical characterization, along with potentiodynamic polarization tests. Furthermore, some specimens in both coating systems were intentionally damaged and exposed to 1000 h of salt spray and immersion testing and analyzed with scanning electron microscopy. Immersion testing yielded similar results for both coatings, while salt spray testing unveiled significant differences and highlighted the susceptibility of the Zn-15Al to salt spray in both undamaged and damaged states. The continuously refreshed salt spray electrolyte hindered stable corrosion product formation, allowing chloride penetration and increased corrosion in Zn-15Al. Conversely, the Zn-Al pseudo-alloy coating formed Al (OH)3, acting as a barrier against chloride penetration during salt spray and offering superior protection. In summary, salt spray testing proved more aggressive than immersion when evaluating Zn-Al coatings with high zinc content primarily relying on active dissolution for corrosion protection. 
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