Effect of mechanical polishing on corrosion behavior of Hastelloy C22 coating prepared by high power diode laser cladding

Hastelloy C22 coatings were prepared on mild steel by high power diode laser cladding technique. In order to investigate the effect of mechanical polishing on corrosion behavior, the coatings with original surface (coating C1) and new surfaces after mechanical polishing away of 0.3 mm (coating C2) and 0.6 mm (coating C3) in depth were studied. Their microstructures and compositions were measured, and corrosion resistance in seawater was studied. The planar, cellular and dendritic solidifications were found from the coating/substrate interface to the top surface of coatings. In coating C1, smallest size primary solidification containing mainly Ni and largest quantity of eutectic networks composed of Cr, Mo and W are dominant, and harmful carbide M(Cr, W)2C is found. While Mo6Ni6C phase exists only in coatings C2 and C3. The open circuit potential and electrochemical impedance spectroscopy of coating C1 are higher within two days, and then lower later than the other two coatings. Coatings C2 and C3 display larger stable radius of capacitive loop and lower corrosion current density owing to higher contents of Cr and Mo, as well as no harmful carbide at surface, which reveals higher corrosion resistance and lower corrosion rate than coating C1. Consequently, properly mechanical polishing of original coating surface is beneficial for improving its corrosion resistance.