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Corrosion Behavior of Cold-Sprayed 316L Coatings: Effects of Deposition Temperature and Surface Condition
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DOI：10.1007/s11666-026-02299-y.png)
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Abstract
En 中文
The passivation behavior of cold-sprayed 316L stainless steel coatings deposited onto SAE 1020 carbon steel was investigated with particular emphasis on the influence of surface condition and deposition temperature. Coatings produced at gas temperatures of 650-825 °C exhibited thicknesses of ~ 450-520 µm and porosity levels of ~ 5-7 vol.%, with microstructures characterized by interparticle boundaries and incomplete bonding typical of cold-sprayed deposits. Electrochemical performance was evaluated in 0.6 M NaCl solution using open circuit potential (OCP), electrochemical impedance spectroscopy (EIS), and cyclic potentiodynamic polarization (CPP). In the polished condition, the coatings consistently exhibited a shift toward more noble OCP values compared to both the as-sprayed state and the SAE 1020 substrate, indicating enhanced surface stability. Despite moderate polarization resistance and the presence of microstructural heterogeneities, EIS results revealed capacitive responses associated with passive-like surface films. Cyclic polarization further demonstrated that polished coatings are capable of sustaining anodic polarization without abrupt current increase, in contrast to the active behavior of the substrate, and in some cases showed evidence of repassivation. These findings indicate that surface finishing plays a critical role in stabilizing passive-like behavior, even in the presence of residual porosity. Overall, the results demonstrate that polished cold-sprayed 316L coatings effectively promote passivation and significantly improve the corrosion resistance of carbon steel substrates in chloride-containing environments. This work contributes to understanding how surface condition and deposition temperature influence the corrosion behavior of cold-sprayed 316L stainless steel coatings in a chloride-containing environment. While previous studies have focused on post-heat treatments or densification strategies, the present study demonstrates that surface polishing can stabilize passive-like behavior, even in the presence of the porosity and interparticle boundaries typical of cold-sprayed deposits. By combining microstructural characterization with electrochemical tests, this work shows that the protective performance of these coatings cannot be evaluated solely based on the response at rest, but must also consider their ability to passivate upon anodic polarization.
Keywords:
austenitic stainless steel
chloride environment
cold spray
electrochemical impedance spectroscopy
potentiodynamic polarization
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