Plasma thermal spray of ceramic oxide coating on carbon steel with enhanced wear and corrosion resistance for oil and gas applications

In this work, carbon steel surface was coated with Al2O3-40 wt% TiO2 composite using thermal spraying method. The tribological properties of the plasma-sprayed Al2O3-40 wt% TiO2 coating were investigated with a tribometer (pin-on-disc) to evaluate and compare the wear properties of coated and uncoated samples under different loads. Additionally, cumulative weight analysis was done to compare wear loss. The results indicate significant anti-wear improvement with an increase in TiO2 from 13 wt% to 40 wt%. The corrosion on coated and uncoated samples was analyzed using AC and DC methods, namely open circuit potential from potentio-dynamic polarization and electrochemical impedance spectroscopy in 3% NaCl solution for 20 days.