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Effect of surface contamination on the corrosion performance of thermally sprayed aluminium coating in synthetic seawater

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Coating standards specify the required surface conditions needed prior to coating. A maximum amount of soluble salts of 20 mg/m2 is widely adopted as acceptation criteria, according to standard NORSOK M-5011. However, meeting these requirements for thermal spray aluminium coatings (TSA) in offshore environments is challenging due to the ubiquitous nature of water-soluble salts.

Product Number: 51323-19138-SG
Author: Adriana Castro-Vargas, Shiladitya Paul
Publication Date: 2023
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This work focuses on the effect of surface contamination prior to coating deposition on the corrosion behaviour of thermal spray aluminium (TSA) coating. TSA coatings (300 μm) were obtained by twin-wire arc spraying AA1050 wires. Substrate surface contamination was performed by immersing grit-blasted S355 steel coupons in artificial seawater for 5, 10 and 20 minutes prior to coating deposition. Measurements of soluble contaminants on steel substrates were made using the Bresle method (ISO8502-6, ISO8502-9). Open circuit potential (OCP) measurements on TSA coatings were carried out at room temperature in synthetic seawater. The corrosion behaviour of the specimens in the 60-day test depended on the amount of surface salt content prior to coating deposition. The data provided useful insight into the corrosion performance which would be beneficial for the offshore industry.

This work focuses on the effect of surface contamination prior to coating deposition on the corrosion behaviour of thermal spray aluminium (TSA) coating. TSA coatings (300 μm) were obtained by twin-wire arc spraying AA1050 wires. Substrate surface contamination was performed by immersing grit-blasted S355 steel coupons in artificial seawater for 5, 10 and 20 minutes prior to coating deposition. Measurements of soluble contaminants on steel substrates were made using the Bresle method (ISO8502-6, ISO8502-9). Open circuit potential (OCP) measurements on TSA coatings were carried out at room temperature in synthetic seawater. The corrosion behaviour of the specimens in the 60-day test depended on the amount of surface salt content prior to coating deposition. The data provided useful insight into the corrosion performance which would be beneficial for the offshore industry.

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