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51318-10653-Corrosion performance of Cold Sprayed Tantalum Coatings

Ta coatings were cold sprayed onto carbon steel and exposed to two different solutions: (i) synthetic seawater and (ii) aqueous 15% HCl to test the suitability to mitigate the corrosion of the substrate.

Product Number: 51318-10653-SG
Author: Shiladitya Paul / Phil McNutt
Publication Date: 2018
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Tantalum (Ta) is known for its inertness, particularly for its resistance to corrosion by most mineral acids, except hydrofluoric acid or acidic solutions containing F- and SO3. Despite its high corrosion resistance, the use of Ta is limited to specialized applications, due to the high material cost. The industrial uptake of Ta can be increased if a dense Ta coating could be achieved by an economical coating production method. To that end, cold spray (or cold gas dynamic spray) offers a possible solution. To test the suitability of cold sprayed Ta to mitigate the corrosion of underlying carbon steel substrate in simulated industrial environments, exposure tests were carried out. Ta coatings were cold sprayed onto carbon steel substrates and exposed to two different solutions: (i) synthetic seawater and (ii) aqueous 15% HCl. After completion of the tests visual examination was carried out. Visual examination revealed that cold sprayed Ta coating is capable of mitigating corrosion of carbon steel in synthetic seawater and 15% HCl environments only when fully dense. Care must be taken to ensure full coverage of the substrate to mitigate galvanic corrosion.

Keywords: cold spray, tantalum coatings, porosity, corrosion rate, electrochemical measurements.

Tantalum (Ta) is known for its inertness, particularly for its resistance to corrosion by most mineral acids, except hydrofluoric acid or acidic solutions containing F- and SO3. Despite its high corrosion resistance, the use of Ta is limited to specialized applications, due to the high material cost. The industrial uptake of Ta can be increased if a dense Ta coating could be achieved by an economical coating production method. To that end, cold spray (or cold gas dynamic spray) offers a possible solution. To test the suitability of cold sprayed Ta to mitigate the corrosion of underlying carbon steel substrate in simulated industrial environments, exposure tests were carried out. Ta coatings were cold sprayed onto carbon steel substrates and exposed to two different solutions: (i) synthetic seawater and (ii) aqueous 15% HCl. After completion of the tests visual examination was carried out. Visual examination revealed that cold sprayed Ta coating is capable of mitigating corrosion of carbon steel in synthetic seawater and 15% HCl environments only when fully dense. Care must be taken to ensure full coverage of the substrate to mitigate galvanic corrosion.

Keywords: cold spray, tantalum coatings, porosity, corrosion rate, electrochemical measurements.

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