Corrosion stability of epoxy coatings on aluminum pretreated by vinyltriethoxysilane

The electrochemical and transport properties and adhesion of epoxy coatings electrodeposited on aluminum pretreated by vinyltriethoxysilane (VTES) were investigated during exposure to 3% NaCl. The VTES films were deposited on aluminum surface from 2% and 5% vinyltriethoxysilane solution. The electrochemical results showed that the pretreatment based on VTES film deposited from 5% solution provides enhanced barrier properties and excellent corrosion protection. The values of diffusion coefficient of water through epoxy coating on this substrate and water content inside the epoxy coating were the smallest, indicating the low porosity of the coating. In addition, the good adhesion was maintained throughout the whole investigated time period.     

The adhesion properties and corrosion performance of differently pretreated epoxy coatings on an aluminium alloy

The influence of various blends of hexafluorozirconic-acid (Zr), polyacrylic-acid (PAA) and polyacrylamide (PAM) pretreatment on the performance of an epoxy coated aluminium substrate was investigated and compared to that of a so-called chromate/phosphate conversion coating (CPCC).Adhesive-strength of epoxy coated substrates was evaluated using pull-off and tape tests. Salt spray, humidity chambers and EIS were employed to characterize corrosion performance of coated substrates with different initial surface pretreatments. Among the Zr-based formulations, PAA/Zr and PAA/PAM/Zr showed the best adhesion strength, while the later revealed a good corrosion performance as well. However, CPCC pretreated sample was still superior in these aspects.     

Inhibition of copper corrosion in sodium chloride solution by the self-assembled monolayer of sodium diethyldithiocarbamate

Sodium diethyldithiocarbamate (DDTC) self-assembled monolayer (SAM) on copper surface has been investigated by SERS and EDS and the results show that DDTC SAM is chemisorbed on copper surface by its S atoms with tilted orientation. Corrosion inhibition ability of DDTC SAM was measured in 3% NaCl solution using electrochemical methods. The impedance results indicate that the maximum inhibition efficiency of DDTC SAM can reach 99%. Quantum chemical calculations show that DDTC has relatively small ΔE between HOMO and LUMO and large negative charge in its two sulfur atoms, which facilitates the formation of a DDTC SAM on copper surface.     

Corrosion inhibition by anionic surfactants of AA2198 Li-containing aluminium alloy in chloride solutions

This paper evaluates the inhibiting action of some anionic surfactants towards AA2198 corrosion in NaCl solutions; the effect of surfactant concentration in relation to chloride amount was determined.On separate electrodes, polarization curves were recorded after 1, 24 and 168 h immersion in the aggressive media, while EIS technique continuously monitored the alloy corrosion process.In general, these substances stifled both the cathodic and anodic processes and noticeably shifted the pitting potential (breakdown potential, E_BR) in the positive direction. The most efficient compounds were N-lauroylsarcosine sodium salt and sodium dodecyl-benzenesulfonate, able to withstand the effects of 0.1 M Cl⁻.     

Corrosion inhibition of mild steel in sodium chloride solution by some zinc complexes

The corrosion inhibitive effect of zinc acetate, zinc acetylacetonate and zinc gluconate on the mild steel immersed in 3.5% NaCl solution was evaluated by electrochemical impedance spectroscopy (EIS). The results revealed superiority of zinc gluconate whilst zinc acetate showed inferior corrosion inhibition. The surface of the samples exposed to the inhibited solutions was analyzed using XRD and SEM techniques. The pH measurement of the test solutions before and after corrosion, also before and after addition of Fe⁺² and Fe⁺³ revealed that the superior inhibition of zinc gluconate is related to formation of insoluble corrosion products on the mild steel surface.     

Inhibition of brass corrosion in sodium chloride solutions by self-assembled silane films

Self-assembled monolayers (SAMs) of 3-mercaptopropyltrimethoxysilane (PropS-SH), dodecyltrimethoxysilane (DTMS), 3-aminopropyl(trimethoxy)silane (APS), and chloropropyl(trimethoxy)silane (CPTMS) were investigated to evaluate the influence of the silane molecule structure towards brass corrosion protection. The results indicated that SAMs of PropS-SH, CPTMS and DTMS inhibited the corrosion of brass in 0.2 M NaCl showing a mixed type behavior, while APS was not a good inhibitor. The inhibitive action of the PropS-SH and DTMS can be explained by chemisorption which obeys the Langmuir adsorption isotherm. The thiolate bond allows a better anchorage of the silane layer to the brass surface than the oxane bond.     

Direct-to-metal UV-cured hybrid coating for the corrosion protection of aircraft aluminium alloy

Finding eco-efficient and environmentally viable alternatives to chromate coatings represents a fundamental milestone in the aerospace industry. Here, we show a chromate-free approach to protective hybrid coatings on aluminium alloy (AA2024-T3) departing from photoinduced sol–gel and cationic polymerizations. Beginning with a film of n-alkyltrimethoxysilane and diepoxy monomer, we rely on photogenerated superacids to induce the single step formation of two inorganic and organic barrier networks. Such system combines the unique aspects of photopolymerization including fast reactions, temporal control, solvent-free composition and temperature independence. Used without chemical conversion coating or anodizing, some films have passed 2000 h of salt spray testing.     

Corrosion protection of steel by epoxy nanocomposite coatings containing various combinations of clay and nanoparticulate zirconia

Epoxy-based nanocomposite coatings containing various amounts of nano-clay and aminopropyltrimethoxy silane (APS) treated zirconia nanoparticles were prepared via slurry method. Morphology and dispersion of nanoparticles within the nanocomposites were evaluated using XRD and TEM analyses. Corrosion performance of mild steel coated specimens was investigated using EIS and EN techniques. The results showed that the simultaneous addition of the spherical ZrO₂ and layered clay nanoparticles promotes the exfoliation of the clay nanoparticles and in so doing improves the corrosion performance of nanocomposite coatings via enhancing the barrier properties and ohmic resistance.     

Protective action towards aluminium corrosion by silanes with a long aliphatic chain

A noticeable and persistent protective action towards aluminium corrosion can be obtained by treatments with silane molecules containing a long aliphatic chain (e.g., n-octadecyl-trimethoxy-silane, C18), which can markedly increase the barrier properties of the silanic coating. At variance with other silanic compounds, the layer of C18, although not uniform, tends to cover the whole aluminium surface completely and, in fact, its EIS spectra initially present one time constant only. It is likely that v.d.Waals interactions between the alkyl chains of C18 can lead to the formation of a polymolecular layer. The aqueous salt solutions may permeate through this layer, but with greater difficulties than in the case of an efficient di-silyl derivative (e.g., 1,2-bis-trioxymethyl-silyl-ethane, BTSE). C18 coatings noticeably retard not only the cathodic oxygen reduction reaction, but also the anodic metal oxidation process. A very prolonged action is also found towards the pitting process in the particularly aggressive chloride solution.     

Corrosion protection of 2024-T3 aluminium alloy by electro-polymerized 3-amino 1,2,4-triazole in sulphate solution containing chloride

Electro-oxidation of 3-amino 1,2,4-triazole (ATA) on Al 2024-T3 alloy carried out simultaneously to the anodizing process in methanol acetate or in aqueous sulphate medium, leads to the formation of Cu^I-ATA complex upon Cu-rich particles. The anodizing film grows, in both media, according to high field-assisted migration mechanism and the potential field is in the order of 10⁶ V cm⁻¹. Significant protective effect of films towards localized corrosion was observed due to Cu^I-ATA and poly(ATA) formations on Cu-rich particles. These complex layers hinder also the oxygen reduction reaction leading to a lower corrosion rate at the open circuit conditions.     

Corrosion and corrosion inhibition of Cu-20%Fe alloy in sodium chloride solution

The electrochemical behavior of copper (Cu), iron (Fe) and Cu-20%Fe alloy was investigated in 1.0 M sodium chloride solution of pH 2. The effect of thiourea (TU) addition on the corrosion rate of the Cu-20%Fe electrode was also studied. Open-circuit potential measurements (OCP), polarization and electrochemical impedance spectroscopy (EIS) were used. The results showed that the corrosion rates of the three electrodes follow the sequence: Cu < Cu-20%Fe < Fe. Potentiostatic polarization of the Cu-20%Fe electrode in the range −0.70 V to −0.45 V (SCE), showed that iron dissolves selectively from the Cu-20%Fe electrode surface and the rate of the selective dissolution reaction depends on the applied potential. At anodic potential of −0.45 V, thiourea molecules adsorb at the alloy surface according to the Langmuir adsorption isotherm. Increasing thiourea concentration (up to 5 mM), decreases the selective dissolution reaction and the inhibition efficiency η reach 91%. At [TU] > 5 mM, the dissolution rate of the Cu-20%Fe electrode increases due to formation of soluble thiourea complexes. At cathodic (−0.6 V), the inhibition efficiency of thiourea decreases markedly owing to a decrease of the rate of the selective dissolution reaction and/or desorption of thiourea molecules. The results indicated that thiourea acts mainly as inhibitor of the selective dissolution reaction of the Cu-20%Fe electrode in chloride solution.     

Multifunctional epoxy coatings combining a mixture of traps and inhibitor loaded nanocontainers for corrosion protection of AA2024-T3

This work aims at investigating the corrosion protection effectiveness of multifunctional epoxy coatings modified with pigments such as ceramic nanocontainers loaded with corrosion inhibitor, chloride and water traps, applied on AA2024-T3. Characterizations on the morphology, composition and structure of the coatings were conducted. The corrosion resistance was studied by electrochemical impedance spectroscopy, localized electrochemical impedance spectroscopy and scanning vibrating electrode technique. The mechanical behaviour of the coatings was examined through nanoindentation and nanoscratching tests. Electrochemical and nanomechanical testing results, evidenced the improvement of the corrosion protective properties and mechanical behaviour of the coatings in the presence of the various pigments.     

Effect of small amounts of alloyed tin on the electrochemical behaviour of aluminium in sodium chloride solution

Binary model AlSn alloys containing 30–1000 ppm (by weight) Sn were investigated by electrochemical polarization in 5 wt% chloride solution and subsequent characterization of corrosion morphology. In the homogenized and rolled condition, tin concentration only slightly affected electrochemical behaviour up to 500 ppm, and the pitting potentials were all about −0.8 V_SCE. However, alloy containing 1000 ppm Sn was significantly activated by lowering of the passivity-breakdown potential to −1.38 V_SCE. Annealing at 300 °C caused significant segregation of Sn to the metal surface, and all specimens, independent of bulk Sn concentration, became nearly similarly active with breakdown potentials around −1.2 V_SCE. Corrosion on 300 °C-annealed specimens was uniformly distributed by polarization below the bulk pitting potential of −0.76 V_SCE. Moreover, the activation effect was temporary, and corrosion was significantly reduced as the segregated Sn was etched away from the surface. Thick oxide, formed during water quenching on high Sn concentration samples, containing 500 and 1000 ppm Sn, introduced partial passivation during polarization test. Annealing at 600 °C caused increasing activation with increasing Sn concentration, caused by Sn enrichment at the metal surface by dealloying of aluminium during anodic polarization in chloride solution. Corrosion was localized in the form of grain boundary corrosion for alloyed Sn concentration less than and equal to 500 ppm and pitting following the triple grain boundaries for 1000 ppm.     

Inhibition by tetradecylpyridinium bromide of the corrosion of aluminium in hydrochloric acid solution

The inhibition effect of tetradecylpyridinium bromide (TDPB) on the corrosion of aluminium in 1.0 M HCl solution was studied by weight loss, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS) methods. The results show that TDPB is a very good inhibitor at little concentrations, and the adsorption of TDPB on aluminium surface obeys Langmuir adsorption isotherm. Polarization curves reveal that TDPB behaves as a cathodic inhibitor. EIS spectra consist of large capacitive loop at high frequencies followed by a large inductive one at low frequency values, and confirm the inhibitive ability.     

Corrosion evaluation of microarc oxidation coatings formed on 2024 aluminium alloy

Dense alumina ceramic coatings of 7 μm thickness were fabricated on 2024 aluminium alloy by microarc oxidation (MAO). The corrosion behaviour of the MAO coated alloys was evaluated using potentiodynamic polarisation and EIS measurements. The results show that the corrosion process of the coated alloy can be divided into three stages: (1) the initial stage (the first 2-6 h of immersion): penetration of corrosion medium into the aluminium alloy was inhibited by coating; (2) the second stage (after 24 h of immersion), corrosion medium penetrated to attack the interface between the substrate and the coating; (3) the final stage (after about 96 h): corrosion process was controlled by the diffusion of corrosion products.     

Corrosion behaviour of sintered NdFeB deposited with an aluminium coating

A protective, pure Al coating was deposited by direct current (DC) magnetron sputtering onto sintered NdFeB magnets. Separated, single phases of sintered NdFeB (the Nd-rich phase, the B-rich phase and the matrix phase) were prepared by arc melting for open circuit potential (OCP) tests. The corrosion process of the sintered NdFeB magnets coated with Al (Al/NdFeB) was studied experimentally. It was found that the corrosion process can be divided into three different stages. The Al coating cannot provide complete sacrificial protection for the sintered NdFeB magnets.     

The evaluation of coating performance by the variations of phase angles in middle and high frequency domains of EIS

Electrochemical impedance spectra (EIS) of six coating systems in 3.5% NaCl solution were measured and the relations between coating resistances and phase angles at different frequencies were analyzed. The results indicated that in middle frequency range, the phase angle and the coating resistance show similar decreasing tendencies. For the coating systems studied, the variation of phase angles at 10 Hz with immersion time was very close to the variation of coating resistance, hence may qualitatively reflect the coating performance. For the studied coating systems, the phase angle at 10 Hz decreased continuously from the beginning, indicating the permeation of the coating system by the electrolytes. When the phase angle reached a relatively stable stage, for different coating systems which was below 40°–20°, meaning the coating has been permeated through and electrochemical reactions under the coatings occurred. In addition, the phase angle at 15 kHz may reflect the state of coating in later stage. These phase angle parameters may be used as quick measurements to evaluate coating performance.     

Corrosion protection of aluminium alloy 2024-T3 in 0.05 M NaCl by cerium cinnamate

The corrosion protection of AA 2024-T3 in 0.05 M NaCl by cerium cinnamate has been studied. Polarization measurements demonstrate that cerium cinnamate is markedly effective for suppressing anodic process of the alloy corrosion during the initial 72 h of immersion. The protection mechanism during the immersion period appears to involve two stages: the deposition of cerium cinnamate, and then hydrolysis of cerium ions forming a cerium oxide/hydroxide, prevailing over the foregoing deposition. This study also elucidates the inhibition effect of cerium cinnamate on the early corrosion attack occurred from the second phase particles by X-ray photoelectron spectroscopy and electron-probe microanalysis.     

Corrosion resistance of lamellar aluminium pigments coated by SiO2 by sol–gel method

The aluminium pigments were coated with SiO₂ by sol–gel method to improve their stability. The effects of formulation factors, such as medium of reaction, adding sequence of catalyst and number of coating, were investigated. The stability of the coated aluminium pigments in acid was examined by measuring the hydrogen generation amount. It was found that the coating layer formation is due to the condensation of tetraethyl orthosilicate (TEOS) to form a dense 3D cross-linked layer on the surface of aluminium. The optimized sequence of adding catalysts would be hydrochloride first, then ammonia. Stability tests confirmed that the aluminium pigments have better corrosion resistance after coating with SiO₂.     

Corrosion inhibition of Armco iron by 2-mercaptobenzimidazole in sodium chloride 3% media

The effect of 2-mercaptobenzimidazole (2MBI) on the corrosion of Armco iron in NaCl media has been investigated in relation to the concentration of the inhibitor by various corrosion monitoring techniques. Surface morphology was studied by scanning electron microscopy (SEM). Results obtained revealed that 2MBI is a good anodic inhibitor. The addition of increasing concentrations of 2MBI moves the corrosion potential towards positive values and reduces the corrosion rate. EIS results show that the changes in the impedance parameters (R_t and C_dl) with concentrations of 2MBI is indicative of the adsorption of these molecules leading to the formation of a protective layer on iron surface. The adsorption of this compound is also found to obey Langmuir’s adsorption isotherm in NaCl.