In this work, functionally graded lanthanum magnesium hexaluminate (LaMgAl₁₁O₁₉)/yttria-stabilised zirconia (YSZ) thermal barrier coating (FG-TBC), in as-sprayed and laser-glazed conditions, were investigated for their thermal shock resistance and thermal insulation properties. Results were compared with those of a dual-layered coating of LaMgAl₁₁O₁₉ and YSZ (DC-TBC). Thermal shock tests at 1100 °C revealed that the as-sprayed FG-TBC had improved thermal stability, i.e., higher cycle lifetime than the as-sprayed DC-TBC due to its gradient architecture, which minimised stress concentration across its thickness. In contrast, DC-TBC spalled at the interface due to the difference in the coefficient of thermal expansion between the LaMgAl₁₁O₁₉ and YSZ layers. Laser glazing improved cycle lifetimes of both the types of coatings. Microstructural changes, mainly the formation of segmentation cracks in the laser-glazed surfaces, provided strain tolerance during thermal cycles. Infrared rapid heating of the coatings up to 1000 °C showed that the laser-glazed FG-TBC had better thermal insulation capability, as interlamellar pores entrapped gas and constrained heat transfer across its thickness. From the investigation, it is inferred that (i) FG-TBC has better thermal shock resistance and thermal insulation capability than DC-TBC and (ii) laser glazing can significantly enhance the overall thermal performance of the coatings. Laser-glazed FG-TBC provides the best heat management, and has good potential for applications that require effective heat management, such as in gas turbines.

Purpose: The failure of structures and components made of SS304 steel because of corrosion in the presence of saline water environment is still an unsolved issue across the globe. Conventionally, coatings and inhibitors are used to mitigate corrosion. The purpose of this study is to propose a novel method to tackle corrosion by means of micro-patterning on the surface and to explore the relation between surface morphology, corrosion and wetting nature of micro-patterned SS304 Steel.Design/methodology/approach: Groove-shaped micro-patterns were created on SS304 steel surface with varying ridge and channel widths. Wettability studies conducted on flat and micro-patterned steel surfaces using high speed camera. Corrosion tests carried out in saline water using an electrochemical test set-up to quantify the performance of micro-patterned surface over flat surface and scanning electron microscopic analysis to visualize the severity of corrosion on the surfaces of SS304 steel.Findings: Wettability studies showed that the micro-patterned steel surfaces were hydrophobic. Corrosion rates of the micro-patterned steel surfaces were lower by more than an order of magnitude compared to that of the flat steel surface. Scanning electron microscopic analysis revealed that the micro-patterned steel surfaces had less surface damage compared to the flat surface.Originality/value: The author shows that the remarkable corrosion resistance shown by the micro-patterned steel surfaces is attributed to their hydrophobicity, which reduced the contact between the surfaces and the corrosive liquid media. Results from the investigation indicate that micro-patterning of SS304 steel surfaces is an effective route to decrease corrosion.

The 304 Stainless Steel (SS304) is severely affected by salt water corrosion due to its high surface wettability. By reducing its surface wettability, its corrosion can be reduced. To achieve this, topographical modification of the steel surface is an effective route. In this work, SS304 flat surfaces were topographically modified into microgrooves (ridge width 250 μm to 500 μm, groove width 200 μm, width ratio = ridge width/groove width >1). Wire cut electrical discharge machining was used to fabricate the microgrooves. Long-term wetting characteristics and long-term corrosion behaviour of flat surface and microgrooves were studied. The influence of the nature of wetting of the tested surfaces on their corrosion behaviour was examined. The sessile drop method and potentiodynamic polarization tests in sodium chloride (3.5 wt. % NaCl) solution (intermittent and continuous exposures for 168 h) were studied to characterize their wetting and corrosion behaviours, respectively. Topographical modification imparted long-term hydrophobicity and, as a consequence, long-term anticorrosion ability of the steel surface. Micropatterning reduced the corrosion rate by two orders of magnitude due to reduction in interfacial contact area with the corrosive fluid via composite wetting, i.e., solid–liquid–air interface. Microgrooves showed corrosion inhibition efficiency ≥88%, upon long-term exposure to NaCl solution. By comparing the wetting and corrosion behaviours of the microgrooves with those of the previously studied microgrooves (ridge width/groove width <1), it was found that the surface roughness of their ridges strongly influences their wetting and corrosion properties.

Stainless steel 304 (SS304) experiences corrosion when it is exposed to a saline atmosphere, which attains severity due to its high surface wettability. Topographical modification of metallic surfaces is an effective route to reduce wettability and thereby mitigate liquid-mediated corrosion. In this work, topographical modification of stainless steel 304 flat surface in the form of micropillars was done (pillar width: 100 μm, inter-pillar distance: 100 μm and height: 80 μm). Micropillars were fabricated by a chemical etching process. Wetting and corrosion of the micropillars was studied over long-time duration in comparison with flat surface, before and after intermittent and continuous exposures to saline water for 168 h. Wetting was characterized by measuring the static water contact angle on the test surfaces and their corrosion by electrochemical polarization tests (electrolyte: 3.5 wt.% sodium chloride solution). The relationship between the nature of wetting of the test surfaces and their corrosion was examined. Micropillars showed predominantly composite wetting over a long time, which imparted an effective resistance against corrosion over a long time to the SS304 surface. When compared to the flat surface, the corrosion rates of the micropillars were lower by two orders of magnitude, prior to and also upon long-time contact with the NaCl solution. Micropillars lowered corrosion due to composite wetting, i.e., solid-liquid-air interface that reduced the area that was in contact with the NaCl solution. The efficiency of corrosion inhibition (η) of micropillars was 88% before long-time contact, 84% after intermittent contact, and 77% after continuous contact with NaCl solution. Topographical modification in the form of micropillars that can impart composite wetting is an effective route to induce long-term anticorrosion ability to the SS304 surface.