Abstract
Ni60 coatings with the CeO2 mass fractions of 3%, 6%, and 9% were prepared on S355 steel. The microstructure and phases of obtained coatings were analyzed using an ultradepth of field microscope (UDFM) and X–ray diffraction (XRD), respectively. The effects of CeO2 mass fraction on the immersion corrosion behaviors and electrochemical performances of Ni60–CeO2 coatings in 5% NaCl solution were investigated. The results show that the immersion corrosion rates of Ni60–3%CeO2, –6%CeO2 and –9%CeO2 coatings are 37.1, 24.3 and 49.2 μm/year, respectively, in which the immersion corrosion resistance of Ni60–6%CeO2 coating is the best among the three kinds of coatings. The polarization resistances of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings are 169,867, 228,568, and 51,276 Ω⋅cm2, respectively, and the corresponding charge transfer resistances are 2.66 × 105, 6.68 × 105, and 6.40 × 105 Ω⋅cm2, respectively, showing that the Ni60–6%CeO2 coating presents the best electrochemical corrosion resistance in 5% NaCl solution.
1 Introduction
Abundant oil and gas resources are existed in ocean, and offshore platform is indispensable for the development and utilization of ocean resources (He et al. 2019). S355 steel is the main structural steel on offshore platform, which is easily corroded by Cl− in harsh ocean environments (Xin and Veljkovic 2020). As an electrolyte, seawater simultaneously accelerates the electrochemical corrosion process, which severely affects the mechanical properties of S355 steel (Melchers 2005) to lead to structural failure (Arzaghi et al. 2020). Coating technology is used to protect the steel structures from corrosion, which is important to investigate the corrosion behavior and of electrochemical performance of coatings in seawater. Among the various kinds of coatings, Ni–based coatings with high corrosion resistance are widely used on the above corrosion conditions (Jiménez et al. 2017a, 2017b; Wan et al. 2018). Many scholars have investigated the corrosion resistance of Ni–based coatings, and the results indicate that the Ni–based coatings have a more positive potential compared with the substrate in NaCl solution (Jiménez et al. 2017a, 2017b).
In order to further improve the corrosion resistance of Ni–based coating in long term and heavy corrosion protection, CeO2 is added to Ni60 coating to enhance the anticorrosion performance (Kumar et al. 2017; Wang et al. 2017), and there are many researches on the CeO2 as additive to increase the corrosion resistance performance. Hu et al. (2021) investigated the effects of CeO2 addition on the microstructure, corrosion properties of NiCoCrAlY coating, and found that the obtained coating with the CeO2 mass fraction of 80% protected the substrate from corrosion. And Zheng et al. (2020) revealed that the addition of CeO2 transformed the micro arc oxidation (MAO) coating to a selfsealing coating, which significantly increased its corrosion resistance. Li et al. (2019) indicated that the CeO2 enhanced the corrosion resistance of Ni–W coating. The previous studies showed that the addition of CeO2 effectively improved the corrosion resistance of alloy coatings. However, there are few investigations on the CeO2 addition to Ni–based coatings. After consulting the literature, the immersion corrosion and electrochemical corrosion performances of CeO2 reinforced Ni60 coatings have been rarely reported (He et al. 2019), which affects the enhancement of corrosion performance for the Ni60 coating on offshore platform.
In this study, Ni60 coatings with the different CeO2 mass fractions were prepared on S355 steel by LC. The influence of CeO2 mass fraction on the immersion corrosion behaviors and electrochemical performances of Ni60 coatings in 5% NaCl solution were investigated, and the corrosion mechanism was discussed, which provided an effective way for S355 steel in heavy corrosion seawater.
2 Materials and methods
2.1 Coating preparations
The subtract was European standard S355 steel, and the chemical composition of Ni60 powder (wt, %) was: Cr 17.59, Fe 4.41, Si 4.07, B 3.23, C 0.83, the rest was Ni. The CeO2 powder with the mass fractions of 3%, 6% and 9% were added to the Ni60 powder, which were mixed on a QM–3SP04L type planetary ball miller at room temperature. Technological parameters: speed of 500 r⋅min−1; ball diameter of 6 mm; and time of 2 h.
The LC test was performed on a ZKSX–2000W type fiber–coupled LC system with the protection of Ar gas, and the side shaft powder feeding mode was adopted. Technological parameters: laser power of 1400 W; laser wavelength of 1064 nm; spot diameter of 4 mm; Ar gas speed of 10 g⋅min−1; and scanning speed of 5 mm⋅s−1.
After the LC test, the coating samples were obtained and further processed to a specific size by Electric spark cutting, according to the test requirements. The FeCl3 solution was used as corrosive agent to investigate the microstructure of the coating surface and section.
2.2 Characterization methods
The microstructure of obtained coatings were observed using a VHX–700FC type ultradepth of field microscope (UDFM), and the phases were analyzed using a D/max2500PC type X–ray diffraction (XRD). In this case, the dilution ratio of laser cladded Ni60–CeO2 coating was (Huang et al. 2021):
where h was the penetration depth of substrate; and H was the height of laser cladded coating.
The immersion corrosion test was conducted in 5% NaCl solution for 720 h, and the corrosion solution was changed every 168 h. After the immersion corrosion test, the corrosion morphologies and chemical elements were analyzed using a JSM–6360LA type scanning electron microscope (SEM) and energy dispersive spectrometer (EDS), respectively. The corrosion performance was evaluated with the mass loss method, in which the mass loss ΔW before and after the corrosion test was measured using an electronic scale with the accuracy of 0.1 mg. In this case, the corrosion rate was (Jiang et al. 2019):
where A was the corrosion area; t was the corrosion time, and φ was the coating density.
The electrochemical corrosion test was conducted on a CHI660E type electrochemical workstation, where the reference electrode type of Mercury/calomel–saturated KCl, the scan rate was set to 0.001 V/s, test potential range of −400–400 mV, and test time was 3600 s. The polarization and impedance curves were analyzed using a ZSimDemo software.
3 Results and discussion
3.1 SEM and XRD analysis of powders
Figure 1(a) shows the SEM spectra of Ni60 powder. It could be found that the spherical Ni60 powder was distributed uniformly, which was conducive to improving the fluidity of mixed powders; while the CeO2 powder presented the obvious lamellar structure with the small size, as shown in Figure 1(b). Figure 1(c) shows the XRD spectra of mixed powders. The peaks of CeO2, Ni3Fe, Cr23C6, and Ni were detected on the Ni60–3%CeO2, –6%CeO2 and –9%CeO2 mixed powders. The weak peak of CeO2 appeared due to the low content of CeO2, which slightly increased with the increase of CeO2 mass fraction, which had a positive effect on the phase stability of mixed powders (Shu et al. 2020). The results showed that the CeO2 addition had little effect on the phase compositions of mixed powders, and no new phases were found.

SEM images and XRD analysis of Ni60–CeO2 mixed powders.
3.2 Microstructure of coating surfaces and cross–sections
Figure 2 shows the optical micrographs of Ni60 coatings with the different CeO2 mass fractions. The massive and striped crystals were found on the Ni60 coating in Figure 2(a), and the dendritic, massive, and striped crystals were found on the Ni60–3%CeO2 coating in Figure 2(b); while the block and cross shaped crystals appeared on the Ni60–6%CeO2 coating in Figure 2(c), which were orderly arranged and evenly distributed. This was because the grain refinement effect of CeO2 on the Ni60 coating. The massive and granular crystals were observed on the Ni60–9%CeO2 coating in Figure 2(d), and the coating microstructure was changed from massive crystals to particle crystals. The coating structure with the CeO2 mass fraction of 6% was uniform, while that with the CeO2 mass fraction of 9% occurred peeling–offs and cracks, and it integrity was also compromised.

Optical micrographs of Ni60 coating surfaces with different CeO2 mass fractions.
The dilution rate was an important indicator to evaluate the microscopic quality of laser cladded coatings (Liu et al. 2017), where the crystal size decreased with the decrease of dilution rate (He et al. 2019). Figure 3 shows the microstructure of Ni60–CeO2 coating cross–sections. The dilution rates of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings calculated from Eq. (1) were 16.9%, 14.3%, and 18.4%, respectively. Although the high dilution rate produced the effective metallurgical bonding with the substrate; the coating performance was weakened and the cracking tendency increased (Chandran et al. 2011; Fernandes et al. 2012; Zhang et al. 2019). Therefore, the Ni60–6%CeO2 coating exhibited the lowest dilution rate among the three kinds of coatings, which was beneficial to improving its corrosion resistance performance.

Optical micrographs of Ni60 coating cross–sections with different CeO2 mass fractions.
3.3 XRD analysis
Figure 4 shows the XRD patterns of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings. The Ni60–CeO2 coating was composed of γ–(Ni, Fe), Cr23C6 and Ni3Fe, and no significant impurities were detected on the coating. In addition, the peak of γ–(Ni, Fe) reached the highest intensity on the Ni–9%CeO2 coating. The multiple phases coexisted and deviated from the equilibrium solidification process (Lu et al. 2016), and no obvious oxide peaks were found due to the protection of Ar gas (Wang et al. 2020). Besides, the CeO2 peak was not detected on the XRD patterns, which was because the CeO2 was easily decomposed in the LC process (Liu et al. 2019).

XRD analysis of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings.
3.4 Immersion corrosion performances
3.4.1 Corrosion morphologies
Figure 5(a) shows the corrosion morphology of Ni60–3%CeO2 coating. The white corrosion pits were found on the part of A, indicating that the corrosion mechanism was pit corrosion (Li et al. 2014; Zhang and Kong 2018). The large number of flocculent layers with the loose structure were formed the accumulated corrosion products on the coating, which were easily detached, with no effect on the protective coating (Safizadeh et al. 2018). The EDS scan results show that the mass fraction of Ce, Cr, and O were 3.78%, 8.49%, and 5.94%, respectively, which was not enough to form the Cr2O3 passive film. Figure 5(b) shows the corrosion morphology of Ni60–6%CeO2 coating. The coating surface had metallic lusters, and no macroscopic defects were found. However, a small number of corrosion pittings were observed on the part of B. This was because the partially melting particles not only well spread out on the coating surface, but also splashed to form a large number of small particles (Hao et al. 2020). The O mass fraction of 5.26% was less than that in Figure 5(a), which was benefit to preventing the formation of corrosion oxides to further inhibit the coating corrosion. Figure 5(c) shows the corrosion morphology of Ni60–9%CeO2 coating. There were obvious corrosion spots on the part of C, which was easily accumulated by Cl− to form pitting phenomenon. Meanwhile, the mass fraction of O was 26.64%, indicating that there were a lot of corrosion and oxidation products on the coating surface.

SEM images EDS analysis of corrosion products on Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings.
3.4.2 Line scanning analysis of corrosion products
Figure 6(a) shows the EDS scanning position and result of corrosion products on the Ni60–3%CeO2 coating. The concentrations of O, Si and Fe on the corrosion center were relatively high, which was because the concentrations of Ni and Cr outside the corrosion center, formed oxide film to inhibit the internal corrosion of coating. Therefore, there was no obvious corrosion effect outside the corrosion center. Figure 6(b) shows the EDS scanning position and result of corrosion products on the Ni60–6%CeO2 coating. The Fe, C, and Ce were distributed on the vicinity of corrosion gullies, and the coatings were smooth and dense as well as bonding strongly with the substrate. Figure 6(c) shows the EDS scanning position result of corrosion products on the Ni60–9%CeO2 coating. The corrosion grooves appeared on the coating surface, indicating that the corrosion was serious. The Fe, C, O, and Ce were distributed on the corrosion products, which were the Fe compound. From the perspective of different corrosion trends on the coatings, the mass fraction of CeO2 affected the corrosion resistance of Ni60 coating to a certain extent.

Line scanned positions and results on Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings.
Figure 7 shows the XRD patterns of corrosion products on Ni60 coatings with the different CeO2 mass fractions. The phases of corrosion products on the Ni60–3%CeO2 and –9%CeO2 coatings were composed of Ni2.9Cr0.7Fe0.36, Ni3Fe, Cr23C6, and Fe3O4; while that of Ni60–6%CeO2 coating was composed of Ni2.9Cr0.7Fe0.36, Ni3Fe, and Cr23C6. Compared with those of Ni60–3%CeO2 and –9%CeO2 coatings, no Fe3O4 phase was found on the Ni60–6%CeO2 coating. It was concluded that the addition of CeO2 promoted the phase transformation, and had effect on the phase composition of Ni60 coating, in which the CeO2 promoted the phase change and effectively improved the corrosion resistance of Ni60 coating (Rios et al. 2016).

XRD analysis of corrosion products on Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings.
3.5 Electrochemical corrosion performances
3.5.1 Polarization curves
To further understand the electrochemical corrosion resistance of Ni60 coatings with the different CeO2 mass fractions, the electrochemical corrosion test was performed. Figure 8 shows the potentiodynamic polarization curves of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings.

Polarization curves of substrate, Ni60–3%CeO2, –6% CeO2, and –9%CeO2 coatings.
In the electrochemical corrosion process, the oxygen absorption reaction often occurred on the cathode (Xu et al. 2011; Yang et al. 2020). In this case, the CeO2 was almost insoluble in water and acid and did not directly participate in the chemical reactions, which refined the grain and had a positive impact on the corrosion resistance of coatings. The related reaction was showed as follow:
On the polarization curves, the current density of initial part on the anode branch increased rapidly, indicating the uniform corrosion on the active zone (Qiao et al. 2016). The oxidation reaction on the anode was showed as follows:
The OH− in Eq. (3) and the Fe2+ in Eq. (4) were reacted to generate the Fe(OH)2 in Eq. (5), i.e.,
The Fe(OH)2 in Eq. (5) was further oxidized to form the Fe(OH)3, and the corrosion products were the mixed oxides of Fe(OH)2, Fe(OH)3, Fe2O3·nH2O, and Fe3O4·nH2O (Zhou and Kong 2019).
There were Cr and Co on the Ni60–CeO2 coating, in which the Cr was more active than the Co, and the Cr easily lost electrons. The Co accumulated on the coating surface, while the Co was not easily hydrolyzed, which protected the substrate from corrosion. In this case, the ionization reaction of Cr was shown as follows:
The Cr3+ in Eq. (6) and the OH− in Eq. (3) were combined to form the Cr(OH)3 as follow [24]:
The Cr(OH)3 in Eq. (7) was the nominal molecular formula of Cr2O3•3H2O, in which the Cr2O3 passive film with the self–repairing ability protected the coating (Zhang et al. 2019), and the penetration of Cl− was reduced to enhance the corrosion resistance of substrate. In this case, the Cr of Ni60–CeO2 coating produced the Cr2O3 passive film on the coating surface, and the addition of CeO2 promoted the formation of Cr2O3 passive film, which significant enhanced the corrosion resistance of Ni60–CeO2 coating.
In addition, there was a corrosion product scale on the coating surface, which mainly consisted of Cr and O. The passive scale effectively prevented the coating from corrosion or oxidation. This was because the Cr had a high diffusion coefficient and Gibbs free energy of reaction with the O (Zhang and Kong 2018). Therefore, both of them were preferentially oxidized to form the Cr2O3, and the formation process was described as follow (Zhang and Kong 2018):
The related parameters of polarization curves were listed in Table 1, in which the corrosion rate V was calculated from Eq. (2). Although both corrosion potential and corrosion current reflected the trend of corrosion reaction, the results showed that it was not accurate to evaluate the corrosion resistance by the corrosion current density. It was reasonable to evaluate the corrosion resistance by the polarization resistance (RP) (Kong et al. 2021; Safizadeh et al. 2018), and the RP was inversely proportional to the corrosion rate (Mouanga et al. 2010). Compared with the Ni60–3%CeO2, Ni60–9%CeO2 coating and substrate, the Rp of Ni60–6%CeO2 coating was the largest. Therefore, the sequence of electrochemical corrosion resistance for the coatings and substrate were: Ni60–6%CeO2 > Ni60–9%CeO2 > Ni60–3%CeO2 > substrate. Meanwhile, the βa of Ni60–6%CeO2 coating was much larger than that of substrate, indicating that the Ni60–6%CeO2 coating had better corrosion resistance.
Polarization parameters of Ni60–3%CeO2, –6% CeO2, and –9%CeO2 coatings.
Sample | β c /V/decade | β a /V/decade | E corr/V | i corr/A/cm2 | R P/Ω cm2 | V/μm/year |
---|---|---|---|---|---|---|
Substrate | 0.273 | 0.101 | −0.597 | 6.40 × 10−6 | 4979 | ≥350.0 |
Ni60–3%CeO2 | 0.163 | 0.237 | −0.346 | 2.48 × 10−7 | 169,867 | 57.1 |
Ni60–6%CeO2 | 0.150 | 0.277 | −0.382 | 1.85 × 10−7 | 228,568 | 34.3 |
Ni60–9%CeO2 | 0.167 | 0.279 | −0.348 | 8.85 × 10−7 | 51,276 | 49.2 |
3.5.2 Nyquist and Bode plots
Based on electrochemical impedance spectroscopy (EIS), the Nyquist and Bode plots of coatings and substrate were analyzed. Through multiple measurements, the stable data were obtained and the curves were fitted by Zsimdemo–3.30 software. From the introduction to electrochemical impedance, it could be seen that the impedance Z was composed of Zi and partial Zr as follow:
where Zi was the real part and Zr was the imaginary part.
Figure 9(a) shows the Nyquist plots of Ni60–3%CeO2, –6%CeO2, and 9%CeO2 coatings and substrate. The high impedance radius in the low–frequency indicated the better corrosion resistance (Cui et al. 2020; Kong et al. 2022; Zhou and Kong 2019). The impedance radius of Ni60–6%CeO2 coating in the frequency of 0.018 Hz was the largest value, while the substrate was the opposite. The sequence of impedance radius between the coatings and the substrate were: Ni60–6%CeO2 > Ni60–9%CeO2 > Ni60–6%CeO2 > substrate, indicating that the corrosion resistance of Ni60–6%CeO2 coating was stronger, which was consistent with the above polarization curve results. Figure 9(b) shows the Bodo plots of impedance for the Ni60–3%CeO2, –6%CeO2, and 9%CeO2 coatings and substrate versus frequency. The impedance of Ni60–6%CeO2 coating was the highest, indicating that the corrosion resistance of Ni60–6%CeO2 coating was the better the two other coatings (Bahrami et al. 2019). Figure 9(c) shows the phase angle of Ni60–3%CeO2, –6%CeO2, and 9%CeO2 coatings and substrate versus frequency. It was suggested that there were several time constants between the coatings and substrate.

Nyquist and Bodo plots of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings.
The impedance of Ni60–CeO2 coatings and substrate were fitted by equivalent circuit model, as shown in Figure 10, and the fitting data of EIS were listed in Table 2, where the fitting error χ2 in the scale of 10−3 was reasonable (Zhao and Kong 2019; Zhou and Kong 2019). In the fitting process, the parameter “n” in the range of 0–1 was a physical quantity to describe the deviation between the nonideal capacitor and the ideal capacitor (Zhao and Kong 2019). When the “n” was equaled to several special values of 1, −1, and 0, it represented the ideal capacitor, inductance, and pure resistance, respectively. The value of “n” in the coating was closer to 1, which belonged to the ideal capacitor. The Rct played a vital role in the electrochemical corrosion process (Feng et al. 2021), which reflected the charge transfer process at the interface between the solution and the substrate. Compared with those of Ni60–3%CeO2, Ni60–9%CeO2 coatings and substrate, the Rct of Ni60–6%CeO2 coating was the largest, which had the highest corrosion resistance.

Equivalent circuit models of substrate and Ni60–CeO2 coatings.
Impedance fitting data and equivalent circuit parameters of Ni60–3%CeO2, –6%CeO2, and–9%CeO2 coatings.
Sample | R s/Ω cm2 | γ 0pt/Ω sn cm2 | n pt | R Pt/Ω cm2 | γ 0ct/Ω sn cm2 | n ct | R ct/Ω cm2 | χ 2 |
---|---|---|---|---|---|---|---|---|
Substrate | 16.37 | – | – | – | 1.05 × 10−3 | 0.852 | 362.80 | 9.03 × 10−4 |
Ni60–3%CeO2 coating | 31.55 | 4.84 × 10−6 | 0.869 | 31.74 | 1.25 × 10−5 | 0.797 | 2.66 × 105 | 8.83 × 10−4 |
Ni60–6%CeO2 coating | 69.84 | 4.43 × 10−6 | 0.788 | 18,430 | 3.68 × 10−7 | 0.968 | 6.68 × 105 | 9.98 × 10−4 |
Ni60–9%CeO2 coating | 10.44 | 1.14 × 10−6 | 0.6002 | 49.78 | 6.10 × 10−6 | 0.889 | 6.40 × 105 | 4.97 × 10−4 |
4 Conclusions
The Ni60 coatings with the different CeO2 mass fractions were successfully prepared on S355 steel by the LC technique, and the microstructure and corrosion resistance of obtained coatings in 5% NaCl solution are investigated, and the results are applied in the equipments of oil and gas industry, which can effectively improve their corrosion resistance and lengthens the service life. The main conclusions are received as follows:
The laser cladded Ni60–CeO2 coatings are composed of γ–(Ni, Fe), Cr23C6, and Ni3Fe phases, The dilution rates of laser cladded Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings are 16.9%, 14.3%, and 18.4%, respectively, showing that the dilution rate of Ni60–6%CeO2 coating is the lowest value among the three kinds of coating.
The immersion corrosion rates of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings are 37.1, 24.3, and 49.2 μm/year, respectively. In the corrosion process, the combination of CeO2 and Cr2O3 further improves the coating stability, and the Ni60–CeO2 coating exhibits the excellent corrosion resistance performance than the substrate.
The polarization resistances of Ni60–3%CeO2, –6%CeO2, and –9%CeO2 coatings are 169,867, 228,568, and 51,276 Ω⋅cm2, respectively, and the corresponding charge transfer resistances are 2.66 × 105, 6.68 × 105, and 6.40 × 105 Ω⋅cm2, respectively. The Ni60–6%CeO2 coating with the largest polarization resistance and charge transfer resistance presents the highest electrochemical corrosion resistance performance.
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Data availability: Data sharing is not applicable to this article as no datasets were generated or analyzed during the current study.
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Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
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Research funding: None declared.
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Conflicts of interest: The authors declare no conflicts of interest regarding this article.
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© 2022 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- Frontmatter
- Reviews
- Review of passivity and electrochemical properties of nanostructured stainless steels obtained by surface mechanical attrition treatment (SMAT): trend and progress
- Galvanic corrosion based on wire beam electrode technique: progress and prospects
- Efforts made in enhancing corrosion inhibition potential of organic compounds: recent developments and future direction
- Original Articles
- The corrosion behavior of HVOF TiAlNb coating in molten Zn-0.2 wt.% Al
- Pitting initiation on 304 stainless steel in a chloride-contaminated pore solution under alternating temperature conditions
- Immersion corrosion behavior and electrochemical performance of laser cladded Ni60–CeO2 coatings in 5% NaCl solution
- Effect of imidazoline derivatives on the corrosion inhibition of Q235 steel in HCl medium: experimental and theoretical investigation
Artikel in diesem Heft
- Frontmatter
- Reviews
- Review of passivity and electrochemical properties of nanostructured stainless steels obtained by surface mechanical attrition treatment (SMAT): trend and progress
- Galvanic corrosion based on wire beam electrode technique: progress and prospects
- Efforts made in enhancing corrosion inhibition potential of organic compounds: recent developments and future direction
- Original Articles
- The corrosion behavior of HVOF TiAlNb coating in molten Zn-0.2 wt.% Al
- Pitting initiation on 304 stainless steel in a chloride-contaminated pore solution under alternating temperature conditions
- Immersion corrosion behavior and electrochemical performance of laser cladded Ni60–CeO2 coatings in 5% NaCl solution
- Effect of imidazoline derivatives on the corrosion inhibition of Q235 steel in HCl medium: experimental and theoretical investigation