Influence of copper distribution in thermally sprayed Cu-bearing coatings on corrosion and microbial activity
Date
2024
Authors
Huang, H.
Singh, S.
Juhasz, A.
Roccisano, A.
Ang, A.S.M.
Stanford, N.
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Journal article
Citation
Surface and Coatings Technology, 2024; 478(130430):1-12
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Abstract
Microbiologically influenced corrosion (MIC) inside steel pipes used for natural gas transmission is a persistent challenge. In this study, antimicrobial copper (Cu)-bearing coatings were introduced as a viable solution to address the issue. To enhance corrosion resistance while maintaining enduring antimicrobial properties of proposed coatings, two innovative microstructural design strategies were proposed by tailoring Cu distributions: composite coatings and retaining Cu in solid solution. Implementing these strategies, two types of Cu-containing coatings, stainless steel (SS)-Cu composite coatings and Monel 400 coatings with Cu in solid solution were deposited on steel substrates using high velocity oxy-fuel (HVOF) and wire arc spray (WAS) techniques.
The influence of Cu distribution on corrosion resistance, long-term Cu-ion dissolution behavior, and antimicrobial properties of these coatings were systematically investigated. Findings unveiled that irrespective of the employed thermal spray technique, SS-Cu composite coatings exhibited preferential dissolution of Cu due to micro-galvanic effects between Cu and the more noble stainless-steel laminates, significantly enhancing their short-term antimicrobial properties against three different bacterial species. Antimicrobial durability, assessed through long-term salt spray tests, showcased the potential of composite coatings for sustained Cu-ion release.
However, localized corrosion propagation toward the substrate led to significantly expedited coating failure. In contrast, WAS Monel coatings, characterized by Cu in solid solution, demonstrated uniform-dominated corrosion but with enhanced corrosion resistance. Despite reduced antimicrobial efficacy, WAS Monel showed promise for long-term protection against MIC in pipeline environments, striking a balance between corrosion resistance and antimicrobial effectiveness.
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Data source: Supplementary data, https://doi.org/10.1016/j.surfcoat.2024.130430
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Copyright 2024 The Author(s). This is an open access article under the CC BY license. (http://creativecommons.org/licenses/by/4.0/)