Microstructure and Corrosion Behavior of Aluminum Coatings Prepared by High-Efficiency Supersonic Plasma Spraying and Oxygen–Acetylene Flame Spraying

Thermal spraying aluminum coatings have been widely used in the corrosion protection of mild steel in seawater. In this study, high-efficiency supersonic plasma spraying (HESP) and oxygen–acetylene flame spraying (FS) were used to prepare aluminum coatings. The micromorphology of the coatings was analyzed by a scanning electron microscope equipped with an energy-dispersive x-ray spectrometer. The phase identification of the coatings was conducted by an x-ray diffractometer. The Vickers hardness and bonding strength of the coatings were measured by an HMV-2000 Vickers hardness tester and MTS809 universal tensile tester. The corrosion resistance of the coatings was tested by an IM6ex electrochemical workstation. The results show that the aluminum coatings prepared by HESP have a denser structure, higher microhardness, higher bonding strength, and better corrosion resistance than those prepared by the traditional FS. After 480-h immersion in 3.5 wt.% NaCl solution, a dense corrosion product formed on the surface of aluminum coatings prepared by HESP prevents further corrosion of the coatings, but the aluminum coatings sprayed by FS demonstrate a serious pitting phenomenon.