Interface Bonding and Corrosion Resistance of Alumina-Titania Ceramic-Coated Rebars: A First-Principles and Experimental Study
Publication: Journal of Materials in Civil Engineering
Volume 35, Issue 10
Abstract
Corrosion of steel bars embedded in reinforced concrete structures considerably reduces the service life and even causes early failure of the structure. Herein, alumina/titania ceramic coated rebars is investigated in terms of interface bonding and corrosion resistance. By means of first-principles study, the Fe-O interaction at the steel-ceramic interface is probed, illustrating the effect of doped Ti on the thermodynamic stability and interface bonding of interface. Experimentally, the phase transition from to at high temperature is uncovered, which results in the densification and self-repairing of defect regions of the coating. Doped titania can further diminish coating’s porosity and promote the interface bonding, and consequently decay its deterioration after exposure to simulated pore solution. In addition, improving fineness of the precursor can also diminish permeable defects and so exhibits well performance on isolating rebar from electrolyte.
Get full access to this article
View all available purchase options and get full access to this article.
Data Availability Statement
Some or all data, models, or code that support the findings of this study are available from the corresponding author upon reasonable request.
Acknowledgments
This work was supported by NSFC-Shandong Joint Fund Project (No. U2106221), Science and Technology Research and Development Plan of China Railway Corporation (No. N2020G055), and National Postdoctoral Funding Program for Innovative Talents (No. BX2021065).
References
Afshar, A., S. Jahandari, H. Rasekh, M. Shariati, A. Afshar, and A. Shokrgozar. 2020. “Corrosion resistance evaluation of rebars with various primers and coatings in concrete modified with different additives.” Constr. Build. Mater. 262 (Nov): 120034–120058. https://doi.org/10.1016/j.conbuildmat.2020.120034.
Bansal, P., N. P. Padture, and A. Vasiliev. 2003. “Improved interfacial mechanical properties of Al2O3-13wt% TiO2 plasma-sprayed coatings derived from nanocrystalline powders.” Acta Mater. 51 (10): 2959–2970. https://doi.org/10.1016/S1359-6454(03)00109-5.
Basinski, Z. S., W. Hume-Rothery, and A. L. Sutton. 1955. “The lattice expansion of iron.” Math. Phys. Sci. 229 (1179): 459–467. https://doi.org/10.1098/rspa.1955.0102.
Boettger, J. C. 1997. “High-precision, all-electron, full-potential calculation of the equation of state and elastic constants of corundum.” Phys. Rev. B 55 (2): 750. https://doi.org/10.1103/PhysRevB.55.750.
Bolleddu, V., V. Racherla, and P. P. Bandyopadhyay. 2014. “Microstructural and tribological characterization of air plasma sprayed nanostructured alumina–titania coatings deposited with nitrogen and argon as primary plasma gases.” Mater. Des. 59 (Jul): 252–263. https://doi.org/10.1016/j.matdes.2014.02.040.
Chen, Z., X. Guo, L. Zhang, G. Lu, M. Liu, and S. Liu. 2022. “Anticorrosion mechanism of Al-modified phosphate ceramic coating in the high-temperature marine atmosphere.” Surf. Coat. Technol. 441 (Jul): 128572–128588. https://doi.org/10.1016/j.surfcoat.2022.128572.
Christensen, M., S. Dudiy, and G. Wahnström. 2002. “First-principles simulations of metal-ceramic interface adhesion: Co/WC versus Co/TiC.” Phys. Rev. B 65 (4): 045408. https://doi.org/10.1103/PhysRevB.65.045408.
Dang, D. Y., L. Y. Shi, J. L. Fan, and H. J. S. Gong. 2015. “First-principles study of W–TiC interface cohesion.” Surf. Coat. Technol. 276 (Aug): 602–605. https://doi.org/10.1016/j.surfcoat.2015.06.009.
Deng, W., S. Li, G. Hou, X. Liu, X. Zhao, Y. An, H. Zhou, and J. Chen. 2017. “Comparative study on wear behavior of plasma sprayed Al2O3 coatings sliding against different counterparts.” Ceram. Int. 43 (9): 6976–6986. https://doi.org/10.1016/j.ceramint.2017.02.122.
Dong, N., C. Zhang, H. Liu, G. Fan, X. Fang, and P. Han. 2015. “Effects of different alloying additives X (X= Si, Al, V, Ti, Mo, W, Nb, Y) on the adhesive behavior of Fe/Cr2O3 interfaces: A first-principles study.” Comput. Mater. Sci. 109 (Nov): 293–299. https://doi.org/10.1016/j.commatsci.2015.07.031.
García-Alonso, M., M. Escudero, J. Miranda, M. I. Vega, F. Capilla, M. Correia, M. Salta, A. Bennani, and J. J. C. González. 2007. “Corrosion behaviour of new stainless steels reinforcing bars embedded in concrete.” Cem. Concr. Res. 37 (10): 1463–1471. https://doi.org/10.1016/j.cemconres.2007.06.003.
Gell, M., E. H. Jordan, Y. H. Sohn, D. Goberman, L. Shaw, and T. Xiao. 2001. “Development and implementation of plasma sprayed nanostructured ceramic coatings.” Surf. Coat. Technol. 146 (Sep): 48–54. https://doi.org/10.1016/S0257-8972(01)01470-0.
Goberman, D., Y. H. Sohn, L. Shaw, E. Jordan, and M. Gell. 2002. “Microstructure development of Al2O3–13wt.% TiO2 plasma sprayed coatings derived from nanocrystalline powders.” Acta Mater. 50 (5): 1141–1152. https://doi.org/10.1016/S1359-6454(01)00414-1.
Góral, A., W. Żórawski, and L. Lityńska-Dobrzyńska. 2014. “Study of the microstructure of plasma sprayed coatings obtained from Al2O3–13TiO2 nanostructured and conventional powders.” Mater. Charact. 96 (Jun): 234–240. https://doi.org/10.1016/j.matchar.2014.08.016.
Guo, L., R. Liang, Y. Zhang, L. Wang, F. Wang, J. Yen, and J. Jiang. 2023. “Molecular dynamics study on the interaction of tricalcium silicate/polymer composites.” Chem. Phys. Lett. 811 (Jan): 140193. https://doi.org/10.1016/j.cplett.2022.140193.
Häglund, J., A. F. Guillermet, G. Grimvall, and M. Körling. 1993. “Theory of bonding in transition-metal carbides and nitrides.” Phys. Rev. B 48 (16): 11685. https://doi.org/10.1103/PhysRevB.48.11685.
Hong, S., Y. Wu, J. Wu, Y. Zhang, Y. Zheng, J. Li, and J. Lin. 2021. “Microstructure and cavitation erosion behavior of HVOF sprayed ceramic-metal composite coatings for application in hydro-turbines.” Renewable Energy 164 (Feb): 1089–1099. https://doi.org/10.1016/j.renene.2020.08.099.
Ibrahim, A., Z. A. Hamid, and A. A. Aal. 2010. “Investigation of nanostructured and conventional alumina–titania coatings prepared by air plasma spray process.” Mater. Sci. Eng., A 527 (3): 663–668. https://doi.org/10.1016/j.msea.2009.08.054.
Itty, P. A., M. Serdar, C. Meral, D. Parkinson, A. A. MacDowell, D. Bjegović, and P. J. Monteiro. 2014. “In situ 3D monitoring of corrosion on carbon steel and ferritic stainless steel embedded in cement paste.” Corros. Sci. 83 (Mar): 409–418. https://doi.org/10.1016/j.corsci.2014.03.010.
Jamil, H. E., M. F. Montemor, R. Boulif, A. Shriri, and M. Ferreira. 2003. “An electrochemical and analytical approach to the inhibition mechanism of an amino-alcohol-based corrosion inhibitor for reinforced concrete.” Electrochim. Acta 48 (23): 3509–3518. https://doi.org/10.1016/S0013-4686(03)00472-9.
Jia, S., Y. Zou, J. Xu, J. Wang, and L. Yu. 2015. “Effect of TiO2 content on properties of Al2O3 thermal barrier coatings by plasma spraying.” Trans. Nonferrous Met. Soc. China 25 (1): 175–183. https://doi.org/10.1016/S1003-6326(15)63593-2.
Jin, Z., C. Xiong, T. Zhao, Y. Du, X. Zhang, N. Li, Y. Yu, and P. Wang. 2022. “Passivation and depassivation properties of Cr–Mo alloyed corrosion-resistant steel in simulated concrete pore solution.” Cem. Concr. Compos. 126 (Feb): 104375. https://doi.org/10.1016/j.cemconcomp.2021.104375.
Kresse, G., and D. Joubert. 1999. “From ultrasoft pseudopotentials to the projector augmented-wave method.” Phys. Rev. B 59 (3): 1758. https://doi.org/10.1103/PhysRevB.59.1758.
Kusoglu, I. M., E. Celik, H. Cetinel, I. Ozdemir, O. Demirkurt, and K. Onel. 2005. “Wear behavior of flame-sprayed Al2O3–TiO2 coatings on plain carbon steel substrates.” Surf. Coat. Technol. 200 (1–4): 1173–1177. https://doi.org/10.1016/j.surfcoat.2005.02.219.
Misra, V. C., Y. Chakravarthy, N. Khare, K. Singh, and S. Ghorui. 2020. “Strongly adherent Al2O3 coating on SS 316L: Optimization of plasma spray parameters and investigation of unique wear resistance behaviour under air and nitrogen environment.” Ceram. Int. 46 (7): 8658–8668. https://doi.org/10.1016/j.ceramint.2019.12.099.
Oleiwi, H. M., Y. Wang, M. Curioni, X. Chen, G. Yao, L. Augusthus-Nelson, A. Ragazzon-Smith, and I. Shabalin. 2018. “An experimental study of cathodic protection for chloride contaminated reinforced concrete.” Mater. Struct. 51 (6): 1–11. https://doi.org/10.1617/s11527-018-1273-1.
Perdew, J. P., K. Burke, and M. Ernzerhof. 1996. “Generalized gradient approximation made simple.” Phys. Rev. Lett. 77 (18): 3865. https://doi.org/10.1103/PhysRevLett.77.3865.
Quazi, M. M., M. A. Fazal, A. S. Haseeb, F. Yusof, H. H. Masjuki, and A. Arslan. 2016. “Laser-based surface modifications of aluminum and its alloys.” Crit. Rev. Solid State Mater. Sci. 41 (2): 106–131. https://doi.org/10.1080/10408436.2015.1076716.
Salman, S., R. Köse, L. Urtekin, and F. Findik. 2006. “An investigation of different ceramic coating thermal properties.” Mater. Des. 27 (7): 585–590. https://doi.org/10.1016/j.matdes.2004.12.010.
Shi, X., N. Xie, K. Fortune, and J. Gong. 2012. “Durability of steel reinforced concrete in chloride environments: An overview.” Constr. Build. Mater. 30 (May): 125–138. https://doi.org/10.1016/j.conbuildmat.2011.12.038.
Siegel, D. J., L. G. Hector Jr., and J. B. Adams. 2002. “Adhesion, atomic structure, and bonding at the Al (111)/α−Al2O3 (0001) interface: A first principles study.” Phys. Rev. B 65 (8): 085415. https://doi.org/10.1103/PhysRevB.65.085415.
Straumanis, M. E., and D. C. Kim. 1969. “Lattice constants, thermal expansion coefficients, densities and perfection of structure of pure iron and of iron loaded with hydrogen.” Int. J. Mater. Res. 60 (4): 272–277. https://doi.org/10.1515/ijmr-1969-600404.
Šuopys, A., L. Marcinauskas, V. Grigaitienė, R. Kėželis, M. Aikas, R. Uscila, S. Tučkutė, and M. Lelis. 2021. “The effect of heat treatment on the microstructure and phase composition of plasma sprayed Al2O3 and Al2O3-TiO2 coatings for applications in biomass firing plants.” Coatings 11 (11): 1289–1305. https://doi.org/10.3390/coatings11111289.
Tanaka, S., R. Yang, M. Kohyama, T. Sasaki, K. Matsunaga, and Y. Ikuhara. 2004. “First-principles characterization of atomic structure of Al2O3 (0001)/Cu nano-hetero interface.” Mater. Trans. 45 (7): 1973–1977. https://doi.org/10.2320/matertrans.45.1973.
Tang, F., X. Cheng, G. Chen, R. K. Brow, J. S. Volz, and M. L. Koenigstein. 2013. “Electrochemical behavior of enamel-coated carbon steel in simulated concrete pore water solution with various chloride concentrations.” Electrochim. Acta 92 (Mar): 36–46. https://doi.org/10.1016/j.electacta.2012.12.125.
Tian, W., Y. Wang, Y. Yang, and C. Li. 2009. “Toughening and strengthening mechanism of plasma sprayed nanostructured Al2O3–13 wt.% TiO2 coatings.” Surf. Coat. Technol. 204 (5): 642–649. https://doi.org/10.1016/j.surfcoat.2009.08.045.
Volpi, E., A. Olietti, M. Stefanoni, and S. P. Trasatti. 2015. “Electrochemical characterization of mild steel in alkaline solutions simulating concrete environment.” J. Electroanal. Chem. 736 (Jan): 38–46. https://doi.org/10.1016/j.jelechem.2014.10.023.
Vural, M., S. I. Zeytin, and A. H. Ucisik. 1997. “Plasma-sprayed oxide ceramics on steel substrates.” Surf. Coat. Technol. 97 (1–3): 347–354. https://doi.org/10.1016/S0257-8972(97)00223-5.
Wang, M., and L. L. Shaw. 2007. “Effects of the powder manufacturing method on microstructure and wear performance of plasma sprayed alumina–titania coatings.” Surf. Coat. Technol. 202 (1): 34–44. https://doi.org/10.1016/j.surfcoat.2007.04.057.
Wang, Y., S. Jiang, M. Wang, S. Wang, T. D. Xiao, and P. R. Strutt. 2000. “Abrasive wear characteristics of plasma sprayed nanostructured alumina/titania coatings.” Wear 237 (2): 176–185. https://doi.org/10.1016/S0043-1648(99)00323-3.
Wang, Y., Z. Jiang, X. Liu, and Z. Yao. 2009a. “Influence of treating frequency on microstructure and properties of Al2O3 coating on 304 stainless steel by cathodic plasma electrolytic deposition.” Appl. Surf. Sci. 255 (21): 8836–8840. https://doi.org/10.1016/j.apsusc.2009.06.069.
Wang, Y., W. Tian, T. Zhang, and Y. Yang. 2009b. “Microstructure, spallation and corrosion of plasma sprayed Al2O3–13% TiO2 coatings.” Corros. Sci. 51 (12): 2924–2931. https://doi.org/10.1016/j.corsci.2009.08.005.
Westergård, R., N. Axén, U. Wiklund, and S. Hogmark. 2000. “An evaluation of plasma sprayed ceramic coatings by erosion, abrasion and bend testing.” Wear 246 (1–2): 12–19. https://doi.org/10.1016/S0043-1648(00)00506-8.
Xia, J., W. Jin, and L. Li. 2011. “Shear performance of reinforced concrete beams with corroded stirrups in chloride environment.” Corros. Sci. 53 (5): 1794–1805. https://doi.org/10.1016/j.corsci.2011.01.058.
Xiao, M. X., M. Zhao, X. Y. Lang, Y. Zhu, and Q. Jiang. 2012. “Improvement of electromigration reliability and diffusion of Cu films using coherent Cu (1 1 1)/Cr2O3 (0 0 0 1) interfaces.” Chem. Phys. Lett. 542 (Aug): 85–88. https://doi.org/10.1016/j.cplett.2012.05.071.
Zavareh, M. A., A. A. D. M. Sarhan, B. B. Abd Razak, and W. J. Basirun. 2014. “Plasma thermal spray of ceramic oxide coating on carbon steel with enhanced wear and corrosion resistance for oil and gas applications.” Ceram. Int. 40 (9): 14267–14277. https://doi.org/10.1016/j.ceramint.2014.06.017.
Zhang, Y., L. Guo, J. Shi, Q. Luo, J. Jiang, and D. Hou. 2022a. “Full process of calcium silicate hydrate decalcification: Molecular structure, dynamics, and mechanical properties.” Cem. Concr. Res. 161 (Nov): 106964. https://doi.org/10.1016/j.cemconres.2022.106964.
Zhang, Y., Z. Yang, and J. Jiang. 2022b. “Insight into ions adsorption at the CSH gel-aqueous electrolyte interface: From atomic-scale mechanism to macroscopic phenomena.” Constr. Build. Mater. 321 (Mar): 126179. https://doi.org/10.1016/j.conbuildmat.2021.126179.
Zhang, Y., Q. Zhang, D. Hou, and J. Zhang. 2020a. “Tuning interfacial structure and mechanical properties of graphene oxide sheets/polymer nanocomposites by controlling functional groups of polymer.” Appl. Surf. Sci. 504 (Feb): 144152. https://doi.org/10.1016/j.apsusc.2019.144152.
Zhang, Z., F. Wang, Y. Liu, S. Wu, W. Li, W. Sun, D. Guo, and J. Jiang. 2018. “Molecule adsorption and corrosion mechanism of steel under protection of inhibitor in a simulated concrete solution with 3.5% NaCl.” RSC Adv. 8 (37): 20648–20654. https://doi.org/10.1039/C8RA03235A.
Zhang, Z., F. Wang, S. Wu, and J. Jiang. 2020b. “Three-dimensional reconstruction and porosity calculation of ceramic coating: Nondestructive X-ray computed tomography.” J. Inorg. Mater. 35 (9): 1059–1063. https://doi.org/10.15541/jim20190534.
Zhukovskii, Y. F., E. A. Kotomin, B. Herschend, K. Hermansson, and P. Jacobs. 2002. “The adhesion properties of the Ag/α-Al2O3 (0001) interface: An Ab initio study.” Surf. Sci. 513 (2): 343–358. https://doi.org/10.1016/S0039-6028(02)01778-8.
Zou, G., Q. Wang, G. Wang, W. Liu, S. Zhang, Z. Ai, H. Chen, H. Ma, and D. Song. 2023. “Revealing excellent passivation performance of a novel Cr-alloyed steel rebar in carbonized concrete environment.” J. Mater. Res. Technol. 23 (Aug): 1848–1861. https://doi.org/10.1016/j.jmrt.2023.01.118.
Information & Authors
Information
Published In
Journal of Materials in Civil Engineering
Volume 35 • Issue 10 • October 2023
Copyright
© 2023 American Society of Civil Engineers.
History
Received: Sep 14, 2022
Accepted: Mar 9, 2023
Published online: Jul 21, 2023
Published in print: Oct 1, 2023
Discussion open until: Dec 21, 2023
Authors
Metrics & Citations
Metrics
Citations
Download citation
If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.