Growth Kinetics of Calcareous Deposits on Thermally Sprayed Aluminum Coatings in Natural Seawater

Abstract

The formation of calcareous deposits on thermally sprayed aluminum (TSA)-coated surfaces immersed in natural seawater and connected to a cathodic protection system is a recurring issue. There is at present limited knowledge on the calcareous deposits’ formation kinetics on TSA in natural seawater following prolonged exposure at different temperatures. In this study, bare 25Cr super-duplex stainless steel (SDSS) and TSA-coated SDSS tube coupons (with and without a silicone-based sealer) were exposed to natural seawater under potentiostatic cathodic protection (CP) and open-circuit potential (OCP) conditions at different temperatures (i.e., 20°C, 35°C, 60°C, and 80°C) for 1.5 y. The coupons were extracted at various intervals to construct growth kinetics curves under various test conditions. The deposits were subsequently examined using scanning electron microscopy, energy dispersive spectroscopy, and x-ray diffraction. For all of the specimens, the deposits on the exposed surfaces increased with exposure time. Fewer deposits were seen under CP conditions than OCP at low temperatures (20°C and 35°C), whereas more deposits were observed with CP than those at OCP at high temperatures (60°C and 80°C). Last, a recommended protection potential of −0.90 VSSC (VAg/AgCl) and cathodic current density values of −8 mA/m2 and −15 mA/m2 were obtained based on the findings of this study.