A typical structure of thermal spray coatings consisted of molten particles; semi-molten particles; oxides; pores and cracks. These factors caused the porosity of sprayed coatings; leading to a great influence on the coating properties; especially their wear-corrosion resistance. In this study; a post-spray sealing treatment of Cr3C2-NiCr/Al2O3-TiO2 plasma sprayed coatings was carried out; then their corrosion properties were evaluated; before and after the treatment. For sealing process; aluminum phosphate (APP) containing aluminum oxide (Al2O3) nanoparticles (~10 nm) was used. The permeability of APP into the sprayed coating was analyzed by scanning electron microscopy coupled with energy dispersive spectroscopy (SEM-EDS). The treatment efficiency for porosity and corrosion resistance of sprayed coatings were evaluated by electrochemical measurements; such as the potentiodynamic polarization and electrochemical impedance spectroscopy. In addition; the wear-corrosion resistance of the sealed coating was examinated in 3.5 wt.% NaCl circulation solution containing 0.25 wt.% SiO2 particles. The obtained results showed that APP penetrated deeply through the sprayed coating. The incorporation of Al2O3 nanoparticles into APP sealant enhanced the treatment efficiency of porosity for sprayed coating. The effect of the post-treatment on corrosion protection of the sprayed coating has been discussed.

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