Analysis of corrosion resistance of powder coatings for protection of forestry machine parts

The article considers the efficiency of using protective corrosion-resistant powder coatings applied to steel structural elements of forestry machines by cold gas-dynamic spraying (CGDS). To apply the protective coatings, 32 samples measuring 100×20×3 mm were made of Ст3сп steel. A low-pressure CGDS unit «Dimet-405» was used for spraying. The study considered 4 types of coating: copper-based – C-01-01; zinc – Z-00- 11; nickel – N3-00-02; aluminum with added zinc – A-80-13. For each type of powder coating, a morphological analysis of the particles was performed and the granulometric composition was determined. The resulting samples were tested under the following conditions: salt fog, salt fog and air, and sea water. The duration of corrosion tests was 720 hours. Based on the test results, the values of corrosion losses of the samples were determined. The obtained data were statistically processed. In addition, a metallographic analysis of the samples was carried out. The best corrosion resistance in all tests was shown by samples with zinc-based (Z-00-11) and aluminum-zinc (A-80-13) coatings. The results of the metallographic analysis showed that no steel corrosion centers were detected on the samples with zinc-based and aluminum-zinc coatings after the tests were completed, and the corrosion losses were caused by the thinning of the protective coatings as a result of exposure to an aggressive environment. At the same time, obvious steel corrosion centers were present on the remaining samples. The results of the study showed that composite coatings based on zinc and aluminum are the most preferable for steel structural elements of forestry machines.

1. Alkhimov A.P., Gulidov A.I., Kosarev V.F., Nesterovich N.I. Features of microparticle deformation upon impact with a solid barrier. Applied Mechanics and Technical Physics, 2000, vol. 41, no. 1, pp. 204–209. (In Russ.)

2. Alkhimov A.P., Klinkov S.V., Kosarev V.F., Fomin V.M. Cold gas-dynamic spraying. Theory and practice. Moscow: Fizmatlit, 2010. 536 p. (In Russ.)

3. Assadi H., Gartner F., Stoltenhoff T., Kreye H. Bonding mechanism in cold gas spraying. Acta Materialia, 2003, vol. 51, no. 15, pp. 4379–4394.

4. Baldanov K.P., Buraev M.K., Ryazanov P.G. On the calculation of parameters of cold gas-dynamic spraying of machine parts using the DIMET-405 installation. Bulletin of VSGUTU, 2019, no. 1(72), pp. 69–73. (In Russ.)

5. Champagne V., Helfritch D. The unique abilities of cold spray deposition. International Materials Reviews, 2016, vol. 61 (7), pp. 437–455. DOI: 10.1080/09506608.2016.1194948.

6. De Force B., Eden T., Potter J. Cold spray Al-5% Mg coatings for the corrosion protection of magnesium alloys. Journal of Thermal Spray Technology, 2011, vol. 20, no. 6, pp. 1352–1358.

7. Gerashchenkov D.A. Wear- and corrosion-resistant aluminum-based alloy for nanostructured coatings: patent 2413024 Russian Federation; decl. 11/16/09; publ. 02/27/11. (In Russ.)

8. Ghelichi R., Bagherifard S., Guagliano M., Verani M. Numerical simulation of cold spray coating. Surface and Coatings Technology, 2011, vol. 205, pp. 5294–5301.

9. Jodoin B., Raletz F., Vardelle M. Cold spray modeling and validation using an optical diagnostic method. Surface and Coatings Technology, 2006, vol. 200, iss. 14– 15, pp. 4424–4432.

10. Katanoda H., Fukuhara M., Iino N. Numerical study of combination parameters for particle impact velocity and temperature in cold spray. Journal of Thermal Spray Technology, 2007, vol. 16, no. 5–6, pp. 627–633. DOI: 10.1007/s11666-007-9087-7.

11. King P., Bae G., Zahiri S., Jahedi M., Lee C. An experimental and finite element study of cold spray copper impact onto two aluminum substrates. Journal of Thermal Spray Technology, 2010, vol. 19, no. 3, pp. 620–634.

12. Koh P.K., Cheang P., Loke K., Yu S., Siao Ming Ang A. Deposition of amorphous aluminium powder using cold spray. Thermal Spray 2012: Proceedings from the Int. Thermal Spray Conf. and Exposition. Houston, 2012, pp. 22–24.

13. Lee K.A., Jung D.J., Park D.Y., Kang W.G., Lee J.K., Kim H.J. Study on the fabrication and physical properties of cold sprayed, Cu-based amorphous coating. Journal of Physics: Conference Series, 2009, vol. 144, pp. 12–15.

14. Li C.-J., Yang G.-J., Gao P.-H., Ma J., Wang Y.-Y., Li C.-X. Characterization of nanostructured WC-codeposited by cold spraying. Journal of Thermal Spray Technology, 2007, vol. 16, no. 5–6, pp. 1011–1020.

15. Li W.Y., Zhang C., Li C.J., Liao H.L. Modelling aspects of high velocity impact of particles in cold spraying by explicit finite element analysis. Journal of Thermal Spray Technology, 2009, vol. 18, no. 5–6, pp. 921–933.

16. Li W.Y., Zhang D.D., Huang C.J., Yin S., Yu M., Wang F.F., Liao H.L. Modelling of impact behaviour of cold spray particles: review. Surface Engineering, 2014, vol. 30, no. 5, pp. 299–308.

17. Pavlov I.S. Determination of the influence of technological parameters of spraying modes on the structure and properties of functional coatings based on Al2O3 and Cu obtained by the method of cold gas-dynamic low-pressure spraying. International Research Journal, 2023, no. 4 (130), pp. 1–15. (In Russ.)

18. Rahmati S., Ghaei A. The use of particle/substrate material models in simulation of cold-gas dynamic-spray process. Journal of Thermal Spray Technology, 2014, vol. 23, no. 3, pp. 530–540.

19. Schmidt T., Assadi H., Gärtner F., Richter H., Stoltenhoff T., Kreye H., Klassen T. From particle acceleration to impact and bonding in cold spraying. Journal of Thermal Spray Technology, 2009, vol. 18, no. 5–6, pp. 794–808.