Article, 2016

Preparation and Performance of Plasma/Polymer Composite Coatings on Magnesium Alloy

Journal of Materials Engineering and Performance, ISSN 1544-1024, 1059-9495, Volume 25, 9, Pages 3948-3959, 10.1007/s11665-016-2247-5

Contributors

Bakhsheshi-Rad, Hamid Reza 0000-0002-0719-6312 (Corresponding author) [1] Hamzah, Esah Binti [2] Bagheriyan, S. [3] Daroonparvar, Mohammad Reza [2] [4] [5] Kasiri-Asgarani, Masoud 0000-0002-9105-7162 [1] Shah, A. M. [2] Medraj, Mamoun M 0000-0001-7570-3868 [6] [7]

Affiliations

  1. [1] Islamic Azad University, Isfahan
    2. [NORA names: Iran; Asia, Middle East];
  2. [2] University of Technology Malaysia
    3. [NORA names: Malaysia; Asia, South];
  3. [3] Islamic Azad University, Karaj
    4. [NORA names: Iran; Asia, Middle East];
  4. [4] Islamic Azad University, Tehran
    5. [NORA names: Iran; Asia, Middle East];
  5. [5] University of Southern Denmark
    6. [NORA names: SDU University of Southern Denmark; University; Denmark; Europe, EU; Nordic; OECD];

Abstract

A triplex plasma (NiCoCrAlHfYSi/Al2O3·13%TiO2)/polycaprolactone composite coating was successfully deposited on a Mg-1.2Ca alloy by a combination of atmospheric plasma spraying and dip-coating techniques. The NiCoCrAlHfYSi (MCrAlHYS) coating, as the first layer, contained a large number of voids, globular porosities, and micro-cracks with a thickness of 40-50 μm, while the Al2O3·13%TiO2 coating, as the second layer, presented a unique bimodal microstructure with a thickness of 70-80 μm. The top layer was a hydrophobic polymer, which effectively sealed the porosities of plasma layers. The results of micro-hardness and bonding strength tests showed that the plasma coating presented excellent hardness (870 HV) and good bonding strength (14.8 MPa). However, the plasma/polymer coatings interface exhibited low bonding strength (8.6 MPa). The polymer coating formed thick layer (100-110 μm) that homogeneously covered the surface of the plasma layers. Contact angle measurement showed that polymer coating over plasma layers significantly decreased surface wettability. The corrosion current density (icorr) of an uncoated sample (262.7 µA/cm2) decreased to 76.9 µA/cm2 after plasma coatings were applied. However, it was found that the icorr decreased significantly to 0.002 µA/cm2 after polymer sealing of the porous plasma layers.

Keywords

HV, alloy, angle measurements, atmospheric plasma spraying, bimodal microstructure, bond strength, coating, coating interface, combination, composite coatings, contact, contact angle measurements, corrosion, corrosion current density, current density, decreased surface wettability, density, dip-coating technique, excellent hardness, hardness, hydrophobic polymers, interface, layer, lowest bond strength, magnesium, measurements, micro-cracks, micro-hardness, microstructure, performance, plasma, plasma coatings, plasma layer, plasma spraying, polymer, polymer coating, polymer seal, porosity, preparation, results, results of micro-hardness, samples, seal, spray, strength, surface, surface wettability, technique, thickness, top layer, unique bimodal microstructure, voids, wettability

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