Development of Alumina-Titania Composite Layers on Stainless Steel through the Detonation Spray Method and Investigation of Salt Spray Corrosion Behavior along with Surface Examination

Table 1

Thermal spray coatings of different materials on various substrates.

Base materials	Substance applied	Coating process	Inference	Reference
Boiler steel	Ni-20 Cr	Detonation spraying	The coating demonstrated significant resistance to oxide scale spallation during cyclic exposures	[7]
S355 steel	Tungsten carbide, chromium carbide, and aluminum oxide	High-velocity oxy-fuel	WC-CoCr provides better protection than uncoated steel, whereas Al2O3 provides poor protection	[22]
Hydroturbine steel	Nickel-based coatings	High-velocity flame spray	TiO2 and Al2O3 intense splats were observed evenly. According to micrographs, the interface between the substrate and the coatings was free of breaks	[23]
13Cr4Ni steel	Ni-Al2O3 coatings	High-velocity flame spray	Ni-Al2O3 coating composition with 40 wt. % Al2O3 demonstrated the best resistance to slurry erosion	[24]
17-4 pH stainless steel	Zinc followed by stearic acid	Electrodeposit ion	The coating, as received 17-4 pH stainless steel sample in a simulated seawater medium, demonstrated enhanced coating adhesion and corrosion resistance than other fabricated surfaces	[25]
Invar steel substrates	Fe-based amorphous coating	D-gun spraying and then cryogenic cycling treatment (CCT)	CCT improves the fracture toughness of Fe-based amorphous coatings, the coatings’ ability to resist crack transmission improves significantly, allowing the coatings’ wear resistance to improve significantly	[26]
Martensitic stainless steel	86WC-10Co-4Cr and 75Cr3C2-25NiCr	D-gun spraying	The 75Cr3C2-25NiCr coating on martensitic stainless steel has more wear resistance than cumulative weight loss	[27]
Boiler tube steel	10, 20, and 35 wt% of Cr3C2 in NiCr	High-velocity oxy-fuel	All the coatings on the ASME SA213 T-22 used for the investigation proved corrosion resistance after being exposed to a destructive Na2SO4-V2O5 solution in the furnace for 50 hours at 800°C	[28]
Carbon steel substrates	Fe-Cr-Nb-B alloys	Detonation spraying and spark plasma sintering	Due to small particle bonding strength and incomplete crystallization, which concentrated the consolidated material incompetent of sustaining appreciable plastic deformation, the wear resistance of the sintered Fe66Cr10Nb5B19 alloy was lower than that of the Fe66Cr10Nb5B19 DS coatings	[29]
Stainless steel substrates	SS 444 and SS 316	High-velocity oxy-fuel	The lack of protective passivity in thermal spray coatings is primarily inherited from the atomized powdered stainless steel material	[30]
12Ch18N10 T steel	Al2O3 coatings	Detonation spray	Ensuring high hardness and wear resistance of the D-gun spraying of Al2O3 coating, the volume fraction of α-Al2O3 must be increased	[31]
Al2O3/Al cored wires	Marine steels	Arc spraying	The enhanced tribocorrosion resistance of the Al-20 percent Al2O3 coating is due to the Al matrix’s high hardness in the layer, greater load-bearing capacity, compact structure, and superior wear-induced corrosion resistance	[32]