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Study of Twin Wire Arc Sprayed Zinc/Aluminum Coating on Low Carbon Steel Substrate: Application to Corrosion Protection

Experimental study of twin wire arc sprayed Zn/Al coating on low carbon steel substrate has been undertaken in the present paper. The spray distances have a pronounced effect on the coating microstructure and it’s resistance against corrosion. Structural and surface morphological analyses of the Zn/Al coatings were performed using XRD, SEM, microhardness, metallographic microscope and gravimetric measurement analysis. The XRD analysis shows an effect only on the critallinity of the phases. The results obtained from SEM analysis show that the coating prepared at 100 mm present higher hardness, low porosity fraction compared to other prepared coatings. Metallographic microscopy and gravimetric measurement result reveals that the coating prepared at 100 mm present a best corrosion resistance when exposed to seawater solution. These studies have been made for a spray distance ranging from 100 to 140 mm.