Ceramic coating cracks corrosion

Researchers at

have developed a new ceramic-based coating for steel and superalloys that prevents corrosion, oxidation, carburisation and sulphidation that commonly occur in gas, liquid, steam and other hostile environments.

The new coating bonds with the metal substrate and is “resilient, inexpensive and simple,” said PNNL scientist Chuck Henager. Because the coating is fabricated at significantly lower temperatures than typically required for conventional ceramic coatings, the new process also can save energy and reduce harmful emissions, he said.

Researchers created the coating by mixing a liquid preceramic polymer with aluminium metal-flake powders to form a slurry that can be applied to a metal object by dipping, painting or air-spraying. A low-temperature curing process follows, using a Ruthenium-based catalyst that enables polymer cross-linking and dries the slurry to a green state. The coated steel is then heated in air, nitrogen or argon at 700 to 900 degrees Celsius. The heat converts the green state layer into an aluminium diffusion/reaction layer that permeates the surface of the steel and provides an aluminide surface coating on the steel.