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There has been a dramatic increase in recent years in a demand for tough, wear‐ resistant, abrasion, erosion, and corrosion‐resistant coatings for petroleum, chemical, aerospace industry, and processes encountering harsh environments such as paper and pulp equipment (the ball valve for high‐pressure leaching). Whereas sufficient informa‐ tion on mechanical properties, such as abrasion, wear, and fatigue, has been gathered over the years, work on the resistance of these coatings to erosion and corrosion is seriously lacking. In the work reported, it has been shown that nanostructured TiO2 coatings offer superior physical and mechanical properties compared to conventional TiO2 coatings. Three different types of plasma‐sprayed titanium dioxide coated samples on mild steel substrate were employed for investigation. The feedstocks used were Sulzer Metco nanopowders designated as AE 9340, AE 9342, and AE 9309. Powder 9340 was a precursor. The corrosion resistance of nanostructured TiO2 coating was dictated largely by surface structure and morphology. The distribution and geometry of splat lamellae, contents of unmelted nanoparticles, and magnitude of porosity are the important factors that affect corrosion resistance. TiO2 showed excellent resistance to corrosion in 3% NaCl. The maximum corrosion rate was observed to be 4 mils per year as shown by polarization potential and weight loss studies. The erosion‐corrosion resistance of the plasma‐ sprayed nanostructured titanium dioxide coatings depends largely upon the character‐ istics of feed powder and its reconstitution. Dense, uniform, and evenly dispersed nanostructured constituents provide a high coating integrity, which offers high resistance to erosion‐corrosion. A mechanism of erosion‐corrosion is explained in the chapter with a schematic diagram. The findings show that the nanostructured TiO2 coatings offer superior resistance to corrosion, erosion, and environmental degradation.

Mechanism of Corrosion and Erosion Resistance of Plasma‐ Sprayed Nanostructured Coatings