Effect of CeO2 on the H2O/NaCl-Induced Corrosion Behavior of Ni-Co Coating at 650 °C

doi:10.1007/s40195-025-01818-0

Abstract

Abstract:

The corrosion behavior of Ni-Co-CeO₂ composite coating was investigated under a simulated high-temperature marine atmosphere alongside Ni-Co coating. The corrosion kinetics, phase composition and microstructure evolution of the coatings were analyzed. A multi-layered oxide scale formed due to the synergistic corrosion by H₂O and NaCl. The growth mechanism of the Co₃O₄, Fe₃O₄, Fe₂O₃, CoFe₂O₄, NiFe₂O₄ and NiO in the scale was proposed according to the distribution of the CeO₂ particles. Compared to Ni-Co cating, the Ni-Co-CeO₂ coating exhibited superior corrosion resistance in the H₂O/NaCl steam, which is beacause the CeO₂ exerted a blocking effect on retarding the diffusion of Fe atoms and corrosive medium, contributing to a reduced corrosion rate and an improved oxide adhesion compared to Ni-Co coating.

Key words: H₂O/NaCl-induced corrosion, Composite coatings, Transmission electron microscopy (TEM), Corrosion mechanism

Yifei Gao, Peng Zhang, Pan Ren, Yingfei Yang, Guofeng Han, Wenbo Du, Wei Li, Qiwei Wang. Effect of CeO₂ on the H₂O/NaCl-Induced Corrosion Behavior of Ni-Co Coating at 650 °C[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(4): 672-690.

Figures/Tables 19

Table 1 Normal composition of the carbon steel substrate (wt%)

C	Cr	Si	Mn	Mo	V	Ni	Fe
7	1.5	6.2	3	7.5	5	6.5	Bal.

Table 2 Composition of the plating solution and deposition parameters for Ni-Co coating and Ni-Co-CeO2 composite coating

Compositions and plating condition	Parameters
H₃BO₃	15-30 g/L
NiCl₂·6H₂O	30-40 g/L
NiSO₄·6H₂O	200-250 g/L
CoSO₄·7H₂O	5-9 g/L
SDS	0.1-0.2 g/L
Temperature	50-60 °C
pH	3-5
Average current density	0.01-0.02 A/cm²
Duty cycle	50%
Frequency	2000 Hz
Agitation rate	400 r/min
Average current density	0.01-0.02 A/cm²

Fig. 1 Schematic diagram of the test device of H2O/NaCl-induced corrosion

Fig. 2 Surface and cross-sectional morphologies of the as-prepared Ni-Co coating a, c and Ni-Co-CeO2 coating b, d

Table 3 Composition of the coating surface in Fig. 2a and 2b by EDS mapping (at.%)

Coatings	Ni	Co	Ce	O	Ratio of Co to Ni
Ni-Co coating	83.79	16.21	-	-	0.19
Ni-Co-CeO₂ coating	67.01	17.13	15.36	0.50	0.25

Fig. 3 XRD patterns of the Ni-Co and Ni-Co-CeO2 coatings a and the amplified peaks of (111) and (311) b

Fig. 4 EBSD maps showing the band contrast (BC maps), average grain size, and grain orientation maps (IPF maps) of Ni-Co coating a, c, e and Ni-Co-CeO2 coating b, d, f

Fig. 5Mass change curve a and the logarithm of the mass gain b of the Ni-Co coating and Ni-Co-CeO2 coatings during the H2O/NaCl-induced corrosion at 650 °C

Fig. 6 Macroscopic morphologies evolution of the Ni-Co coating a and Ni-Co-CeO2 coating b during the H2O/NaCl-induced corrosion at 650 °C

Fig. 7 XRD patterns of the Ni-Co coating a and Ni-Co-CeO2 coating b during the H2O/NaCl-induced corrosion at 650 °C for different duration

Fig. 8 Surface morphologies, cross-sectional morphologies and corresponding EDS line profile along the oxide scale of Ni-Co coating a, c, e and Ni-Co-CeO2 coating b, d, f after H2O/NaCl-induced corrosion at 650 °C for 20 h

Table 4 Composition of the tagged zone in Figs. 8-10 by EDS (at.%, normalized by Fe, Co, Ni, O, Ce, Cl)

Points	Fe	Co	Ni	O	Ce	Cl
1	4.21	46.24	22.35	27.20	-	-
2	-	24.40	11.21	48.88	15.51	-
3	4.61	53.64	-	41.75	-	-
4	2.32	28.33	0.92	65.21	3.22	-
5	58.51	32.16	-	8.07	-	1.26
6	30.80	14.58	-	53.68	-	0.94

Fig. 9 Surface morphologies, cross-sectional morphologies and corresponding EDS line profile along the oxide scale of Ni-Co coating a, c, e and Ni-Co-CeO2 coating b, d, f after H2O/NaCl-induced corrosion at 650 °C for 60 h

Fig. 10 Surface morphologies, cross-sectional morphologies and corresponding EDS line profile along the oxide scale of Ni-Co coating a, c, e and Ni-Co-CeO2 coating b, d, f after H2O/NaCl-induced corrosion at 650 °C for 200 h

Fig. 11 Bright field morphology of the oxide scale a and the diffraction patterns of the tagged zone in different oxide layers b-1, c-2, d-3, e-4, f-5, g-6 on Ni-Co-CeO2 coating after H2O/NaCl-induced corrosion at 650 °C for 200 h

Fig. 12 Elemental distribution in the oxide scale of Ni-Co-CeO2 coating after H2O/NaCl-induced corrosion at 650 °C for 200 h by EDX mapping

Fig. 13 Elemental distribution of the Ni-Co coating a and Ni-Co-CeO2 coating b after H2O/NaCl-induced corrosion at 650 °C for 200 h by EPMA

Fig. 14 ΔGθ of forming oxides and chlorides as a function of temperature (standardized to consuming 1 mol O2, 1 mol Cl2 or 1 mol HCl)

Fig. 15 Schematic diagram of the corrosion mechanism for the Ni-Co a and Ni-Co-CeO2 b coatings under the H2O/NaCl-induced corrosion at 650 °C

References 59

[1]	A.H.I. Mourad, A. Almomani, I.A. Sheikh, A.H. Elsheikh, Eng. Fail. Anal. 146, 107107 (2023)
[2]	F. Xu, N. Ding, N. Li, L. Liu, N. Hou, N. Xu, W. Guo, L. Tian, H. Xu, C.M.L. Wu, Eng. Fail. Anal. 152, 107518 (2023)
[3]	A. Dalmau, C. Richard, Tribol. Int. 121, 167 (2018)
[4]	B. Fotovvati, N. Namdari, J. Manuf. Mater. Process. 3, 28 (2019)
[5]	A. Karimzadeh, M. Aliofkhazraei, F.C. Walsh, Surf. Coat. Technol. 372, 463 (2019)
[6]	F. Mohsenifar, H. Ebrahimifar, A. Irannejad, Acta Metall. Sin.-Engl. Lett. 37, 872 (2024)
[7]	A.R. Shetty, A.C. Hegde, Hegde, Surf. Coat. Technol. 322, 99 (2017)
[8]	S. Sattawitchayapit, V. Yordsri, T. Wutikhun, T. Chookajorn, Wear 538, 205184 (2024)
[9]	X. Yang, X. Lu, W. Zhang, X. Guo, J. Ren, H. Xue, F. Tang, J. Nanopart. Res. 25, 152 (2023)
[10]	P. Zhang, Y. Zhao, J. Huang, J. Li, L. Cao, J. Liu, G. Han, W. Du, L. Chen, L. Xiao, Surf. Coat. Technol. 467, 129678 (2023)
[11]	J.H. Choi, G. Gyawali, D.R. Dhakal, B. Joshi, S.W. Lee, Acta Metall. Sin.-Engl. Lett. 33, 573 (2020)
[12]	N.S. Mbugua, M. Kang, Y. Zhang, N.J. Ndiithi, G.V. Bertrand, L. Yao, Materials 13, 3475 (2020)
[13]	K.C. Zhou, M. Li, Z.Y. Li, Trans. Nonferrous Met. Soc. China 21, 1052 (2011)
[14]	X. Zhuang, Y. Tan, X. You, P. Li, L. Zhao, C. Cui, H. Zhang, H. Cui, Vacuum 189, 110219 (2021)
[15]	D. Golodnitsky, N. Gudin, G. Volyanuk, Plating. Surf. Finish. 85, 65 (1998)
[16]	L. Chang, M. An, S. Shi, Mater. Chem. Phys. 94, 125 (2005)
[17]	S.M.A. Shibli, K.S. Chinchu, M.A. Sha, Acta Metall. Sin.-Engl. Lett. 32, 481 (2019)
[18]	W.C. Sun, Mater. Sci. Forum 694, 799 (2011)
[19]	M. Srivastava, J. Balaraju, B. Ravisankar, C. Anandan, V.W. Grips, Appl. Surf. Sci. 263, 597 (2012)
[20]	D. Maruoka, M. Nanko, Ceram. Int. 49, 28629 (2023)
[21]	L. Ma, K. Zhou, Z. Li, Corros. Sci. 53, 2357 (2011)
[22]	S. Shanmugasamy, K. Balakrishnan, A. Subasri, S. Ramalingam, A. Subramania, J. Rare Earths 36, 1319 (2018)
[23]	S. Purkayastha, D.K. Dwivedi, J. Tribol. 136, 011602 (2014)
[24]	Q. Zheng, S. Mei, Z. Xiao, Z. Hu, Z. Chen, Q. Xu, A. Guryev, B. Lygdenov, Ceram. Int. 50, 8760 (2024)
[25]	A.A. Ansari, J.P. Labis, M. Alam, S.M. Ramay, N. Ahmad, A. Mahmood, Acta Metall. Sin.-Engl. Lett. 29, 265 (2016)
[26]	Y. Xue, S. Wang, Y. Xue, L. Cao, M. Nie, Y. Jin, Adv. Eng. Mater. 22, 2000402 (2020)
[27]	M. Sheng, W. Weng, Y. Wang, Q. Wu, S. Hou, J. Alloy. Compd. 743, 682 (2018)
[28]	B. Li, D. Li, T. Mei, W. Zhang, Res. Phys. 13, 102375 (2019)
[29]	R. Shakoor, R. Kahraman, U.S. Waware, Y. Wang, W. Gao, Mater. Des. 59, 421 (2014)
[30]	Y.J. Xue, X.Z. Jia, Y.W. Zhou, W. Ma, J.S. Li, Surf. Coat. Technol. 200, 5677 (2006)
[31]	H.M. Jin, S.H. Jiang, L.N. Zhang, J. Rare Earths 27, 109 (2009)
[32]	Y. Li, S. Geng, G. Chen, Int. J. Hydrog. Energy 43, 12811 (2018)
[33]	M. Hajizadeh-Oghaz, R.S. Razavi, A. Ghasemi, Z. Valefi, Ceram. Int. 42, 5433 (2016)
[34]	H. Gitanjaly, S. Singh, S. Singh, Mater. High Temp. 27, 109 (2010)
[35]	W. Chen, W. Wang, L. Liu, R. Liu, Y. Cui, Z. Chen, Q. Wang, F. Wang, Corros. Sci. 226, 111677 (2024)
[36]	M. Bajt Leban, M. Vončina, T. Kosec, R. Tisu, M. Barborič, J. Medved, High. Temp. Corros. Mater. 99, 63 (2023)
[37]	J. Guo, Acta Metall. Sin. 46, 513 (2010)
[38]	A.A. Ati, Z. Othaman, A. Samavati, J. Mol. Struct. 1052, 177 (2013)
[39]	Y.J. Xue, H.B. Liu, M.M. Lan, J.S. Li, H. Li, Surf. Coat. Technol. 204, 3539 (2010)
[40]	L. Benea, P.L. Bonora, A. Borello, S. Martelli, F. Wenger, P. Ponthiaux, J. Galland, Solid. State Ionics 151, 89 (2002)
[41]	J. Sun, S. Jiang, H. Yu, S. Liu, J. Gong, C. Sun, Corros. Sci. 139, 172 (2018)
[42]	D.J. Young, High Temperature Oxidation and Corrosion of Metals, vol. 1 (Elsevier 2008), p. iii
[43]	F. Kaschel, R. Vijayaraghavan, P. McNally, D. Dowling, M. Celikin, Mater. Sci. Eng. A 819, 141534 (2021)
[44]	M.S. Safavi, M. Tanhaei, M.F. Ahmadipour, R.G. Adli, S. Mahdavi, F.C. Walsh, Surf. Coat. Technol. 382, 125153 (2020)
[45]	S.M. Dezfuli, M. Sabzi, Ceram. Int. 45, 21835 (2019)
[46]	W. Ke, W. Jiang, Y. Han, Y. Chen, Y. Lao, J. Alloy. Compd. 946, 169407 (2023)
[47]	Y. Xi, K. Gao, X. Pang, H. Yang, X. Xiong, H. Li, A.A. Volinsky, Ceram. Int. 43, 11992 (2017)
[48]	Z. Zhang, C. Jiang, Z. Liao, G. Wei, Mater. Today. Commun. 27, 102403 (2021)
[49]	L. Xu, R. Wang, M. Gen, L. Lu, G. Han, Materials 12, 3240 (2019)
[50]	F. Khorashadizade, H. Saghafian, S. Rastegari, J. Alloy. Compd. 770, 98 (2019)
[51]	A. Kamboj, Y. Raghupathy, M. Rekha, C. Srivastava, JOM 69, 1149 (2017)
[52]	A. Aliyu, C. Srivastava, Surf. Coat. Technol. 405, 126596 (2021)
[53]	G. Wang, D. Li, Y. Zuo, Y. Tang, X. Zhang, X. Zhao, Coatings 10, 161 (2020)
[54]	C. de Alwis, M. Trought, E.J. Crumlin, S. Nemsak, K.A. Perrine, Appl. Surf. Sci. 612, 155596 (2023)
[55]	I.E. Wachs, K. Routray, ACS Catal. 2, 1235 (2012)
[56]	L. Yuan, Y. Wang, R. Cai, Q. Jiang, J. Wang, B. Li, A. Sharma, G. Zhou, Mater. Sci. Eng. B 177, 327 (2012)
[57]	C. Jiang, M. Feng, M. Chen, K. Chen, S. Geng, F. Wang, Corros. Sci. 187, 109484 (2021)
[58]	W. Sun, J. Wang, L. Yang, M. Chen, Z. Bao, C. Zheng, S. Zhu, F. Wang, Corros. Sci. 161, 108187 (2019)
[59]	M. Zhang, L. Xin, X. Ding, S. Zhu, F. Wang, J. Alloy. Compd. 734, 307 (2018)

Effect of CeO₂ on the H₂O/NaCl-Induced Corrosion Behavior of Ni-Co Coating at 650 °C

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 19

References 59

Related Articles 11

Recommended Articles

Metrics

Comments

[1]	Xiaoming Liu, Fengyang Quan, Yuan Gao, Shaodong Zhang, Jianbin Wang, Zhijun Wang, Junjie Li, Feng He, Jincheng Wang. Comparison of Hot Corrosion Behavior of Ni₃₆Fe₃₄Al₁₇Cr₁₀Mo₁Ti₂ and Ni₃₄Co₂₅Fe₁₂Al₁₅Cr₁₂W₂ Alloys in NaCl-KCl-Na₂SO₄ Salt [J]. Acta Metallurgica Sinica (English Letters), 2025, 38(2): 205-217.
[2]	You Lv, Yupeng Zhang, Xi Liu, Zehua Dong, Xiaorong Zhou, Xinxin Zhang. Effect of Mn Addition and Heat Treatment on the Corrosion Behaviour of Mg-Ag-Mn Alloy [J]. Acta Metallurgica Sinica (English Letters), 2024, 37(4): 665-677.
[3]	L. M. Liu, Y. X. Lai, C. L. Wu, Z. Zhang, J. H. Chen. Anisotropic Inter-granular Corrosion Behaviors and Microstructures of AlMgSiCu Alloy Sheets Made by Thermal-Mechanical Treatments [J]. Acta Metallurgica Sinica (English Letters), 2022, 35(2): 275-284.
[4]	Yunpeng Zeng, Wei Yan, Xianbo Shi, Maocheng Yan, Yiyin Shan, Ke Yang. Enhanced Bio-corrosion Resistance by Cu Alloying in a Micro-alloyed Pipeline Steel [J]. Acta Metallurgica Sinica (English Letters), 2022, 35(10): 1731-1743.
[5]	Xuyang Wang, Jieren Yang, Rui Hu, Zitong Gao, Jinguang Li, Hengzhi Fu. Creep-Induced Phase Instability and Microstructure Evolution of a Nearly Lamellar Ti-45Al-8.5Nb-(W, B, Y) Alloy [J]. Acta Metallurgica Sinica (English Letters), 2020, 33(12): 1591-1600.
[6]	Bao-Jie Wang, Ji-Yu Luan, Dao-Kui Xu, Jie Sun, Chuan-Qiang Li, En-Hou Han. Research Progress on the Corrosion Behavior of Magnesium-Lithium-Based Alloys: A Review [J]. Acta Metallurgica Sinica (English Letters), 2019, 32(1): 1-9.
[7]	Zhang Jingqing, Hu Rui, Wang Jian, Li Jinshan. Corrosion Behavior of Ni-20Cr-18W-1Mo Superalloy in Supercritical Water [J]. Acta Metallurgica Sinica (English Letters), 2014, 27(6): 1046-1056.
[8]	Sabale Sandip, Khot Vishwajeet, Jadhav Vidhya, Zhu Xiaoli, Xu Yanhong. Synthesis and Properties of Monodisperse Superparamagnetic Mg_0.8Mn_0.2Fe₂O₄ Nanoparticles Using Polyol Reflux Method [J]. Acta Metallurgica Sinica (English Letters), 2014, 27(6): 1122-1126.
[9]	Shuai WANG, Lei WANG1, Yang LIU, Guohua XU, Beijiang ZHANG, Guangpu ZHAO. Nucleation mechanism of a nickel-base superalloy during dynamic recrystallization [J]. Acta Metallurgica Sinica (English Letters), 2011, 24(4): 295-300.
[10]	S.J. Yan, W.H. Tian , L. Qi. PREPARATION OF TEM THIN FOIL CONTAINING POWDER PARTICLE BY ELECTRODEPOSITION METHOD [J]. Acta Metallurgica Sinica (English Letters), 2006, 19(2): 98-104 .
[11]	C.Leygraf, J.Pan, M.Femenia. MICROSCOPIC CORROSION STUDIES OF DUPLEX STAINLESS STEELS [J]. Acta Metallurgica Sinica (English Letters), 2004, 17(5): 625-631 .