Influence of TiC Addition on Corrosion and Tribocorrosion Resistance of Cr2Ti-NiAl Electrospark Coatings

Marine and coastal infrastructures usually suffer from synergetic effect of corrosion and wear known as tribocorrosion, which imposes strict requirements on the structural materials used. To overcome this problem, novel composite wear- and corrosion-resistant xTiC-Fe-CrTiNiAl coatings with different TiC content were successfully developed. The coatings were obtained by the original technology of electrospark deposition in a vacuum using xTiC-Cr2Ti-NiAl (x = 0, 25, 50, 75%) electrodes. The structure and morphology of the coatings were studied in detail by XRD, SEM, and TEM. The effect of TiC content on the tribocorrosion behavior of the coatings was estimated using tribological and electrochemical (under stationary and wear conditions) experiments, as well as impact testing, in artificial seawater. The TiC-free Fe-Cr2Ti-NiAl coating revealed a defective inhomogeneous structure with transverse and longitudinal cracks. Introduction of TiC allowed us to obtain coatings with a dense structure without visible defects and with uniformly distributed carbide grains. The TiC-containing coatings were characterized by a hardness and elastic modulus of up to 10.3 and 158 GPa, respectively. Formation of a composite structure with a heavily alloyed corrosion-resistant matrix based on α-(Fe,Cr) solid solution and uniformly distributed TiC grains led to a significant increase in resistance to stationary corrosion and tribocorrosion in artificial seawater. The best 75TiC-Fe-CrTiNiAl coating demonstrated the lowest corrosion current density values both under stationary (0.03 μA/cm2) and friction conditions (0.8 μA/cm2), and was characterized by both a 2-2.5 times lower wear rate (4 × 10−6 mm3/Nm) compared to AISI 420S steel and 25TiC-Fe-CrTiNiAl and a high fracture toughness.