Corrosion Behavior of Spherical Chromium Carbide Reinforced NiCrBSi Hardmetal Coatings in Sulphuric Acid Solution

Abstract

In the present work, four groups of spherical chromium carbide reinforced NiCrBSi hardmetal coatings were prepared on AISI 4145 steel by plasma transferred arc (PTA) technique. The corrosion behavior of the four as-received hardmetal coatings in 0.5 mol/L H2SO4 solution was investigated by polarization curve and electrochemical impedance spectroscopy (EIS). The results revealed that more Cr-rich carbides (Cr3C2, Cr7C3 and M23(C, B)6) are formed in the chromium carbide reinforced coatings, while for the NiCrBSi hardmetal coating only Cr7C3 carbide was detected by XRD. The polarization results show that the chromium carbide reinforced NiCrBSi hardmetal coatings have positive corrosion potential and lower corrosion current, providing a better protective effect to the substrate metal. The combined effects of Cr-rich carbide ceramic phases and a more stable passive film of Cr2O3 greatly improved the corrosion resistances of the chromium carbide reinforced NiCrBSi hardmetal coatings. The coating with the highest spherical chromium carbide addition has more pores because of the thermal stress due to the difference of thermal expansion coefficient between the NiCrBSi bonding phase and chromium carbide reinforced phase. The negative effects of the pores weaken the corrosion resistance, and the coating with the 30% chromium carbide content shows the best corrosion resistance. For NiCrBSi hardmetal coatings with higher reinforced chromium carbide content, the repeatability of the corrosion current obtained by polarization fitting is not as good as that of coatings with lower chromium carbide content. The repeatability of polarization results becomes worse when the specimens keep in a more stable passive state.