Tecnologia em Metalurgia, Materiais e Mineração
https://tecnologiammm.com.br/article/doi/10.4322/2176-1523.20222769
Tecnologia em Metalurgia, Materiais e Mineração
Artigo Original – Edição especial 75th ABM Annual Congress

Development of Fe-based glass former alloys for thermal spray coatings with optimized corrosion and wear properties

Claudio Shyinti Kiminami, Guilherme Yuuki Koga, Claudemiro Bolfarini, Walter José Botta

Downloads: 0
Views: 2603

Abstract

Corrosion and wear of alloys is a costly and hidden safety risk for components in petrochemical, agroindustry, and mining activities, which are key segments in Brazil and in many countries. Accelerating the development of highperformance and durable ferrous alloys and their insertion into engineering structural applications has never been more important. Glass former steels have drawn considerable attention in recent years, due to the remarkable combinations of strength and degradation control that can be achieved by tailoring corrosion and wear resistances, which places these alloys amongst the durable ferrous alloy ever developed. Recent results from our group indicate that coatings using these alloys can be produced from commercial grade precursors and industrially available thermal spraying routes. The development of Fe-based bulk metallic glass (BMG) alloys for degradation control will open the door to next-generation coatings with unprecedented combinations of corrosion and wear resistances. This work summarizes the development of Fe-based glassy coatings for corrosion and wear control performed in our research group in the last 17 years covering: i) glass forming ability of alloys, ii) development of Fe-based glass former alloys, iii) thermal spraying of Fe-based glass former alloys, and iv) scientific and technological impacts of this research.

Keywords

Amorphous alloys; Metallic glass; Glass forming steel; Surface engineering; Corrosion; Wear

Referências

1 Halak RM, Koga GY. Aços inoxidáveis modificados com boro resistentes à corrosão e ao desgaste para uso como revestimento em componentes da indústria sucroalcoleira [TCC]. São Carlos: UFSCar; 2021.

2 Hays GF. Now is the time. World Corrosion Organization. 2013 [cited 2022 July 2]. Available at: https://corrosion.org/Corrosion+Resources/Publications/_/nowisthetime.pdf

3 Batchelor AW, Loh NL, Chandrasekaran M. Materials degradation and its control by surface engineering. London: Imperial College Press; 2011.

4 Davis JR. Surface engineering for corrosion and wear. Ohio: ASM International; 2001.

5 ANP. Boletim de recursos e reservas de petróleo e gás natural 2017. 2018 [cited 2022 July 2]. Available at: https://www.gov.br/anp/pt-br/centrais-de-conteudo/dados-estatisticos/arquivos-reservas-nacionais-de-petroleo-e-gasnatural/boletim_reservas_2017.pdf

6 ANP. Boletim Reservas. 2017 [cited 2022 July 2]. Available at: http://www.anp.gov.br/images/Dados_Estatisticos/ Reservas/Boletim_Reservas_2017.pdf

7 EIA. What countries are the top producers and consumers of oil. 2018 [cited 2022 July 2]. Available at: https://www.eia.gov/tools/faqs/faq.php?id=709&t=6

8 Food and Agriculture Organization of the United Nations. Crops and livestock products. 2020 [cited 2022 July 2]. Available at: www.fao.org/faostat/en/#data/QC

9 Lima JRF, Silva F. Análise do desgaste abrasivo em rolos de moenda em usinas de cana-de-açúcar: estudo de caso. Rio Verde: Universidade de Rio Verde; 2020 [cited 2022 July 2]. Available at: www.unirv.edu.br/conteudos/fckfiles/files/Jose%20Ricardo.pdf

10 USGS: National Minerals Information Center. Iron ore statistics and information. 2017 [cited 2022 July 2]. Available at: https://minerals.usgs.gov/minerals/pubs/commodity/iron_ore/global_iron_ore_data.pdf

11 World Steel Association. 2018. [cited 2022 July 2]. Available at: https://worldsteel.org/wp-content/uploads/2018-World-Steel-in-Figures.pdf

12 Tan H, Zhang Y, Ma D, Feng YP, Li Y. Optimum glass formation at off-eutectic composition and its relation to skewed eutectic coupled zone in the La based La-Al-(Cu,Ni) pseudo ternary system. Acta Materialia. 2003;51:4551.

13 Hays CC, Kin CP, Johnson WL. Microstructure controlled shear band pattern formation and enhanced plasticity of bulk metallic glasses containing in situ formed ductile phase dendrite dispersions. Physical Review Letters. 2000;84:2901.

14 Lu ZP, Liu CT. A new glass-forming ability criterion for bulk metallic glasses. Acta Materialia. 2002;50:3501-3512.

15 Inoue A, Nishiyama N, Matsuda T. Preparation of bulk glassy Pd40Ni10Cu30P20 alloy of 40 mm in diameter by water quenching. Materials Transactions - JIM. 1996;37:181.

16 Egami T, Waseda Y. Atomic size effect on the formability of metallic glasses. Journal of Non-Crystalline Solids. 1984;64:113.

17 Lisboa RD, Bolfarini C, Botta FWJ, Kiminami CS. Topological instability as a criterion for design and selection of aluminum-based glass-former alloys. Applied Physics Letters. 2005;86:211904.

18 Oliveira MF, Pereira FS, Bolfarini C, Kiminami CS, Botta WJ. Topological instability, average electronegativity difference and glass forming ability of amorphous alloys. Intermetallics. 2009;17(4):183-185.

19 Fang S, Xiao X, Xia L, Li W, Dong Y. Relationship between the widths of supercooled liquid regions and bond parameters of Mg-based bulk metallic glasses. Journal of Non-Crystalline Solids. 2003;321(1-2):120-125.

20 Suryanarayana C, Inoue A. Iron-based bulk metallic glasses. International Materials Reviews. 2013;58:131-166.

21 Inoue A, Gook JS. ‘Fe-based ferromagnetic glassy alloys with wide supercooled liquid region. Materials Transactions - JIM. 1995;36:1180-1183.

22 Sá Lisboa RD, Bolfarini C, Botta FWJ, Kiminami CS. Topological instability as a criterion for design and selection of aluminum-based glass-former alloys. Applied Physics Letters. 2005;86:211904.

23 Kiminami CS, Sá Lisboa RD, de Oliveira MF, Bolfarini C, Botta WJ. Topological instability as a criterion for design and selection of easy glass-former compositions in metallic systems. Materials Transactions - JIM. 2007;48:1739-1742.

24 Botta J, Pereira FS, Bolfarini C, Kiminami CS, de Oliveira MF. Topological instability and electronegativity effects on the glass-forming ability of metallic alloys. Philosophical Magazine Letters. 2008;88:785-791.

25 Koga GY, Schulz R, Savoie S, Nascimento ARC, Drolet Y, Bolfarini C, et al. Microstructure and wear behavior of Fe-based amorphous HVOF coatings produced from commercial precursors. Surface and Coatings Technology. 2017;309:938-944.

26 Guo Y, Jorge AM, Costa E, Silva A, Kiminami CS, Bolfarini C, et al. Experimental and thermodynamic investigation of the microstructural evolution of a boron-rich Fe-Cr-Nb-B alloy. Journal of Alloys and Compounds. 2017;713:119-124.

27. Guo Y, Jorge AM Jr, Kiminami CS, Bolfarini C, Botta WJ. On the ternary eutectic reaction in the Fe60Cr8Nb8B24 quaternary alloy. Journal of Alloys and Compounds. 2017;707:281-286.

28 Mendes MAB, Melle AK, Souza CAC, Kiminami CS, Cava RD, Bolfarini C, et al. The effect of cr content on the glass forming ability of Fe68-xCrxNb8B24 x =8,10,12 alloys. Materials Research. 2016;15:1-5.

29 Koga GY, Nogueira RP, Roche V, Yavari AR, Melle AK, Gallego J, et al. Corrosion properties of Fe-Cr-Nb-B amorphous alloys and coatings. Surface and Coatings Technology. 2014;254:238-243.

30 Souza CAC, Bolfarini C, Botta WJ Jr, Lima LRPDA, Oliveira MF, Kiminami CS. Corrosion resistance and glass forming ability of Fe47Co7Cr15M9Si5B15Y2 M=Mo, Nb amorphous alloys. Materials (Basel). 2013;166:1294-1298.

31 Catto FL, Yonamine T, Kiminami CS, Afonso CRM, Botta WJ, Bolfarini C. Amorphous phase formation by spray forming of alloys [Fe0.6Co0.40.75B0.2Si0.05]96Nb4 and Fe66B30Nb4 modified with Ti. Journal of Alloys and Compounds. 2011;509:S148-S154.

32 Rios CT, Kiminami CS, Afonso CRM, Botta WJ Fo, Bolfarini C. Characterization of glass forming alloy Fe43.2Co28.8B19.2Si4.8Nb4 processed by spray forming and wedge mold casting techniques. Materials Science Forum Online. 2011;691:23-26.

33 Kiminami CS, Souza CAC, Bonavina LF, Andrade Lima LRP, Suriñach S, Baró MD, et al. Partial crystallization and corrosion resistance of amorphous Fe-Cr-M-B M=Mo, Nb alloys. Journal of Non-Crystalline Solids. 2010;356:2651-2657.

34 Afonso CRM, Bolfarini C, Botta Filho WJ, Kiminami CS. Spray forming of the glass former Fe83Zr3. 5Nb3. 5B9Cu1 alloy. Materials Science and Engineering A. 2004;375:571-576.

35 Kiminami CS, Afonso CRM, Kaufman MJ, Bolfarini C, Botta Filho WJ. Gas atomization of Fe63Nb10Al4Si3B20 alloy. Journal of Metastable and Nanocrystalline Materials. 2004;20-21:175-182.

36 Bonavina LF, Bolfarini C, Botta WJ, de Almeida ER, Kiminami CS. Microstructural characterization of spray formed Fe66B30Nb4 alloy. Journal of Alloys and Compounds. 2010;495:417-419.

37 Afonso CRM, Bolfarini C, Botta WJ Fo, Kiminami CS. Spray forming of glass former Fe63Nb10Al4Si3B20 alloy. Materials Science and Engineering A. 2007;449:884-889.

38 Afonso CRM, Bolfarini C, Botta WJ Fo, Kiminami CS. In-situ crystallization of amorphous Fe73− xNbxAl4Si3B20 alloys through synchrotron radiation. Journal of Non-Crystalline Solids. 2006;352(32-35):3404-3409.

39 Botta WJ, Berger JE, Kiminami CS, Roche V, Nogueira RP, Bolfarini C. Corrosion resistance of Fe-based amorphous alloys. Journal of Alloys and Compounds. 2014;586:S105-S110.

40 Sigolo E, Soyama J, Zepon G, Kiminami CS, Botta WJ, Bolfarini C. Wear resistant coatings of boron-modified stainless steels deposited by Plasma Transferred Arc. Surface and Coatings Technology. 2016;302:255-264.

41 Guo Y, Jorge AM Jr, Kiminami CS, Bolfarini C, Botta WJ. On the ternary eutectic reaction in the Fe60Cr8 Nb8 B24 quaternary alloy. Journal of Alloys and Compounds. 2017;707:281-286.

42 Koga GY, Savoie S, Nascimento AR, Schulz R, Bolfarini C, Kiminami CS, et al. Microstructure and wear behavior of Fe-based amorphous HVOF coatings produced from commercial precursors. Surface and Coatings Technology. 2017;309:938-944.

43 Inoue A. Amorphous, nanoquasicrystalline and nanocrystalline alloys in Al-based systems. Progress in Materials Science. 1998;43:365.

44 Kim YH, Inoue A, Masumoto T. Increase in mechanical strength of Al–Y–Ni amorphous alloys by dispersion of nanoscale fcc-Al particles. Materials Transactions - JIM. 1991;32:331.

45 Naka M, Hashimoto K, Inoue A, Masumoto T. Corrosion resistance Fe-C alloys containing chromium and/or molybdenum. Journal of Non-Crystalline Solids. 1979;31:347-357.

46 Duarte MJ, Klemm J, Klemm SO, Mayrhofer KJJ, Stratmann M, Borodin S, et al. element-resolved corrosion analysis of stainless-type glass-forming steels. Science. 2013;341:372-376.

47 Gostin PF, Oswald S, Schultz L, Gebert A. Acid corrosion process of Fe-based bulk metallic glass. Corrosion Science. 2012;62:112-121.

48 Zander D, Koster U. Corrosion of amorphous and nanocrystalline Zr-based alloys. Materials Science and Engineering A. 2004;375:53-59.

49 Ha HM, Payer JH. Devitrification of Fe-based amorphous metal SAM 1651: a structural and compositional study. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science. 2009;40(11):2519-2529.

50 Ding J, Inoue A, Han Y, Kong FL, Zhu SL, Wang Z, et al. High entropy effect on structure and properties of (Fe Co, Ni, Cr)-B amorphous alloys. Journal of Alloys and Compounds. 2017;696:345-352.

51 Wang F, Inoue A, Kong FL, Han Y, Zhu SL, Shalaan E, et al. Formation, thermal stability and mechanical properties of high entropy (Fe Co, Ni, Cr, Mo)-B amorphous alloys. Journal of Alloys and Compounds. 2018;732:637-645.

52 Wang F, Inoue A, Kong FL, Zhu SL, Shalaan E, Al-Marzouki F, et al. Formation, stability and ultrahigh strength of novel nanostructured alloys by partial crystallization of high- entropy (Fe0.25Co0.25Ni0.25Cr0.125Mo0.125)86-89B11-14 Amorphous phase. Acta Materialia. 2019;170:50-61.

53 Inoue A, Kong FL, Zhu SL, Shen BL, Churyumov A, Botta WJ. Formation, structure and properties of pseudo-high entropy clustered bulk metallic glasses. Journal of Alloys and Compounds. 2020;820:153164.

54 Koga GY, Travessa D, Zepon G, Coimbra˜o DD, Jorge AM, Berger JE, et al. Corrosion resistance of pseudohigh entropy fe-containing amorphous alloys in chloride-rich media. Journal of Alloys and Compounds. 2021;884:161090.

55 Sugiyama M, Igarashi T, Okano T, Kimura HM, Inoue A. Glassy alloy coating by high velocity thermal powder deposition and its application to lead-free soldering vessel. Matéria (Rio de Janeiro). 2007;46:31-33.

56 Farmer J, Choi JS, Saw C, Haslam J, Day D, Hailey P, et al. Iron-based amorphous metals: high-performance corrosion-resistant material development. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science. 2009;40(6):1289-1305

57 Otsubo F, Era H, Kishitake K. Formation of amorphous Fe-Cr-Mo-8P-2C coatings by the high velocity oxy-fuel process. Journal of Thermal Spray Technology. 2000;9:494-498.

58 Otsubo F, Kishitake K. Corrosion Resistance of Fe-16% Cr-30% Mo-C,B,P amorphous coatings sprayed by HVOF and APS processes. Materials Transactions. 2005;46:80-83.

59 Kobayashi A, Yano S, Kimura HM, Inoue A. Fe-based metallic glass coatings produced by smart plasma spraying process. Materials Science and Engineering B. 2008;148:110-113.

60 Kobayashi A, Yano S, Kimura HM, Inoue A. Mechanical properties of Fe-based metallic glass coatings formed by tunnel type t plasma spraying. Surface and Coatings Technology. 2008;202:2513-2518.

61 Blink J, Farmer J, Choi J, Saw C. Applications in the nuclear industry for thermal spray amorphous metal and ceramic coatings. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science. 2009;40:1344-1358.

62 Zheng ZB, Zheng YG, Sun WH, Wang JQ, Erosion–corrosion of HVOF-sprayed Fe-based amorphous metallic coating under impingement by a sand-containing NaCl solution. Corrosion Science. 2013;76:337-347.

63 Lin J, Wang Z, Lin P, Cheng J, Zhang X, Hong S. Microstructure and cavitation erosion behavior of FeNiCrBSiNbW coating prepared by twin wires arc spraying process. Surface and Coatings Technology. 2014;240:432-436.

64 Koga GY, Ferreira T, Guo Y, Coimbrão DD, Jorge AM Jr, Kiminami CS, et al. Challenges in optimizing the resistance to corrosion and wear of amorphous Fe-Cr-Nb-B alloy containing crystalline phases. Journal of Non-Crystalline Solids. 2021;555:120537.

65 Berger JE, Schulz R, Savoie S, Gallego J, Kiminami CS, Bolfarini C, et al. Wear and corrosion properties of HVOF coatings from Superduplex alloy modified with addition of boron. Surface and Coatings Technology. 2017;309:911-919.

66 Zhang Y, Zuo TT, Tang Z, Gao MC, Dahmen KA, Liaw PK, et al. Microstructures and properties of high-entropy alloys. Progress in Materials Science. 2014;61:1-93.

67 Inoue A, Takeuchi A. Recent development and application products of bulk glassy alloys. Acta Materialia. 2011;59:2243-2267.

68 Guo Y, Koga GY, Jorge ASM Jr, Savoie, RS, Kiminami CS, Bolfarini C, et al. Microstructural investigation of Fe-Cr-Nb-B amorphous / nanocrystalline coating produced by HVOF. Materials & Design. 2016;111:608-615.

69 Koga GY, Jorge AM Jr, Roche V, Nogueira RP, Schulz R, Savoie S, et al. Production and corrosion resistance of thermally sprayed Fe-based amorphous coatings from mechanically milled feedstock powders. Metallurgical and Materials Transactions. A, Physical Metallurgy and Materials Science. 2018;49(10):4860-4870.

70 Geng Y, Wang Y, Qiang J, Zhang G, Dong C, Häussler P. Composition formulas of Fe–B binary amorphous alloys. Journal of Non-Crystalline Solids. 2016;432:453-458.

71 Wu Y, Hui XD, Lu ZP, Liu ZY, Liang L, Chen GL. Effects of metalloid elements on the glass-forming ability of Fe-based alloys. Journal of Alloys and Compounds. 2009;467:187-190.

72 Cantor B. Stable and metastable multicomponent alloys. Annales de Chimie-Science des Materiaux. 2007;32:245-256.

73 Takeuchi A, Wang J, Chen N, Zhang W, Yokoyama Y, Yubuta K, et al. Al0.5TiZrPdCuNi high-entropy HE alloy developed through Ti20Zr20Pd20-Cu20Ni20 HE glassy alloy comprising inter-transition metals. Materials Transactions. 2013;54:776-782.

74 Shen J, Chen Q, Sun J, Fan H, Wang G. Exceptionally high glass-forming ability of an FeCoCrMoCBY alloy. Applied Physics Letters. 2005;86:151907.

75 Huang B, Zhang C, Zhang G, Liao H. Wear and corrosion resistance performance of thermal-sprayed Fe-based amorphous coatings: a review. Surface and Coatings Technology. 2019;377:124896.

76 Koga GY, Bolfarini C, Kiminami CS, Moreira Jorge Jr A, Botta WJ. An overview of thermally sprayed Fe-CrNb-B metallic glass coatings: from the alloy development to the coating’s performance against corrosion and wear. J.Thermal Spray Technology. 2022;31:923-955.

77 Nayak SK, Kumar A, Laha T. Fe-based metallic glass coatings by thermal spraying: a focuese review on corrosion properties and related degradation mechanisms. International Materials Reviews. 2022. In press.

78 Milanez DH, Faria LIL, Leiva DR, Kiminami CS, Botta WJ. Assessing technolgical developments in amorphous/glassy metallic alloys using patent indicators. Journal of Alloys and Compounds. 2017;716:330-335.

79 Oliveira BS, Milanez DH, Leiva DR, Faria LIL, Botta WJ, Kiminami CS. Thermal spraying processes and amorphous alloys: macro-indicators of patent activity. Materials Research. 2017;20:89-95.


Submetido em:
02/07/2022

Aceito em:
09/12/2022

63cecd66a953955dbc7af304 tmm Articles
Links & Downloads

Tecnol. Metal. Mater. Min.

Share this page
Page Sections