The corrosion behavior of plasma-sprayed Ni/Al–Al2O3 and Ni/Al–Al2O3+13 wt.% TiO2 graded ceramic coatings in 5%HCl solution

The corrosion behavior of plasma-sprayed Ni/Al–Al2O3 and Ni/Al–Al2O3+13 wt.% TiO2 graded ceramic coatings in 5%HCl solution was investigated. It was shown that the corrosion resistance of a Ni/Al–Al2O3 graded coating was 130 times that of a single Al2O3 coating. The corrosion resistance of Ni/Al–Al2O3+13%TiO2 graded coatings was increased by 39.2% compared to a Ni/Al–Al2O3 graded coating with the same compositional gradient. The improvement in corrosion resistance of graded ceramic coatings mainly resulted from the change of corrosion behavior due to the change in structure of the coating. The bond layer alloy particles in the transition layers were distributed isolated in the ceramic matrix. Thus, the connected pores in the working layer were actually pseudo-connected pores. As a result, the electrochemical corrosion between the bond layer and the matrix was restrained. In addition, the pseudo-connected porosity in graded coatings lay on not only the open porosity but also the structure of the graded coating.