Effect of thermal spray parameters on corrosion rate for low carbon steel used in marine applications.

This study investigated the corrosion behavior of metallic coatings consisting of Zn powder, which were deposited onto a low carbon steel substrate using the flame thermal spraying technique. Corrosion experiments were performed in salt water using a salty solution of 3.5 percent sodium chloride and one liter of filtered water to evaluate the coated layer's performance. Analysis of the test results enabled estimation of the rate of corrosion and investigation of the properties of the coated layer. Analyzing the test results made it possible to determine the corrosion rate and investigate the coated layer's characteristics. Effects on corrosion rates in the protective coatings layer were influenced by powder flow rate. The metallic coating's microstructure was investigated using SEM. It was discovered from the corrosion resistance and the polarization curves of the steel alloy coated layer that rising in salt solution led to higher corrosion resistance. The coating layer made of zinc powder displays strong corrosion resistance for low carbon steel. It is protected in a solution of 3.5 percent sodium chloride with a thickness of 103 microns, leading to good results. As a result, the coating layer's microstructure was consistent and homogenous, and there were no pores, which led to good corrosion resistance. [ABSTRACT FROM AUTHOR]