Evaluation of the Mechanical and Corrosion Behavior of Twin Wire Arc Sprayed Ni-Al Coatings with Different Al and Mo Content

In this study, the surface properties of marine structures were improved by applying a twin wire arc spray process to high-strength low alloys. The effect of Al and Mo contents in Ni-Al coatings on their mechanical and corrosion behaviors was analyzed using hardness tests, electrochemical experiments, and immersion tests. The increase in Al content resulted in the formation of oxides and intermetallic compounds, leading to a significant improvement in the mechanical properties by approximately 222 HV. Despite a fine galvanic phenomenon causing a decrease in corrosion resistance by up to 8.91%, a higher Al content demonstrated the highest corrosion resistance after high-temperature exposure, with an enhancement of approximately 20.9%, attributed to the formation of an oxide film generated by intermetallic phase transformation. However, the mechanical properties experienced a reduction of 134.3 HV. This study demonstrated a correlation between the microstructure of the coating layers that form passivation films and their respective mechanical and corrosion properties. It also revealed that the content of Al and Mo significantly affects the mechanical and corrosion behavior of Ni-Al coatings.