Evaluation of adhesion of epoxy resin sealant to improve the corrosion resistance of thermal sprayed coatings

The adhesion of coatings on a given substrate has fundamental importance on a coating/substrate system's functionality. The current paper presents the adhesion strength results of FeCr and CoCr-based deposits produced by the electric arc thermal spray process on carbon steel, with an intermediate layer of 95Ni5Al. Three chemical compositions were tested for coating deposition and were characterized using plate and tube specimens made of carbon steel UNS?G10200 to result in a screening of performance. Microstructural evaluation by optical microscopy (OM), scanning electron microscopy (SEM), and X-ray diffraction (XRD) were performed. Coating strength was measured using the standard pull-off test method. The corrosion resistance was analyzed with salt spray exposure, electrochemical polarization, and impedance spectroscopy (EIS) tests. The adhesion strength of FeCr and CoCr alloy coatings shows an overall average tensile strength of 27.2?MPa. All sealed conditions presented low corrosion and the samples with epoxy sealant exhibited a high resistance against corrosion. The X-ray diffraction results have revealed alpha and gamma FeCr alloys and chromite as deposited phases after the coating process.