Enhancement of corrosion resistance on plasma spray coated mild steel substrate exposed to marine environment

Abstract Plasma Spray Coating (PSC) provides enduring protection in mild steel structure and is widely used in various engineering applications. PSC also strengthens the material surface from corrosion damages caused due to atmospheric conditions and also enhances the life span of the material. However, the mild steel substrate gets corroded easily due to the salt content available in the marine solution and environmental changes, thereby forming a rust layers on the surface. Therefore, to avoid this phenomena, metal with highly corrosion resistance need to be used as a coating material for the steel structures installed in marine applications. In line with the context, the present work focuses to enrich the corrosion resistance property and life span of the mild steel structures with nickel alloy coating with a thickness of 100 µm on the surface through plasma spray technique. Corrosion test like salt spray and hot corrosion was determined as per the ASTM standards. Moreover, the morphological structure was also examined using scanning electron microscopy (SEM). The reported results shown that the employment of Ni alloy coating over mild steel substrate improves the corrosion resistance and its life span even during prolonged expose to marine atmosphere