Silicon oxide anticorrosion coating deposition on alloy steel surface by low temperature plasma

In this work, honeycomb-like SiOx coating was successfully prepared on steel surface by atmospheric pressure low temperature plasma jet. The surface morphology, corrosion resistance and stability of the coating were systematically analyzed. In addition, the growth mechanism of the coating was discussed. The analysis revealed that the coatings were primarily composed of Si-O-Si and Si-OH groups, with a minor presence of Si-CH3 moieties. The coating obtained after two deposition cycles exhibits the highest level of uniformity and density, with minimal porosity and superior corrosion resistance. The increase in deposition cycles led to particle aggregation, augmented particle dimensions and porosity, which adversely affected the coating's performance. The dense SiOx coating resulted in a significant reduction in the corrosion current density of the alloy steel, and showed no significant corrosion defects when exposed to the crude oil simulant in 25 °C. The coating simultaneously enhanced the hydrophilicity and oil transfer of the steel surface. Finally, the coating exhibited self-cleaning properties, stability and high potential for safeguarding steel pipes against low-viscosity crude oil contamination. This study provides a general surface modification method for the preparation of corrosion-resistant coatings on metal surfaces under mild conditions.