热浸镀锌层高锰酸盐转化膜工艺

为了进一步提高热浸镀锌层的耐蚀性能,利用化学转化处理方法在热浸镀锌层表面制备了高锰酸盐转化膜.研究了工艺条件对转化膜耐中性盐雾腐蚀性能的影响,确定了最佳工艺为:KMnO<,4>质量浓度20 g/L,处理温度40℃,pH 2.5～3.0,处理时间60 min.采用扫描电镜、能谱、X射线光电子能谱、X射线衍射等技术对转化膜...     

Electrochemical and morphological properties of zirconium conversion coating in the presence of nickel ions on galvanized steel

A hexafluorozirconic acid-based conversion coating was applied on a galvanized steel substrate and the influence of nickel ion from nickel sulfate solution (in zirconium solution and in a separate solution) on the corrosion resistance behavior and morphology of zirconium conversion coating was investigated. Electrochemical impedance spectroscopy and DC polarization were conducted in 3.5 wt% NaCl solution in order to optimize practical conditions of zirconium conversion coating and NiSO₄ solution on the galvanized steel substrate. Field emission scanning electron microscopy and X-ray photoelectron spectroscopy were employed to study the morphology and composition of the coated surfaces. Results revealed that the conversion coating obtained from solution containing zirconium and nickel ions (Zr + Ni) did not improve corrosion resistance and uniformity of the coating in comparison with Zr conversion coating in optimized condition. However, a positive effect was obtained from samples coated with separate solutions of zirconium and nickel (Zr–Ni). Improved corrosion resistance and morphology of Zr-based conversion coating were observed in Ni²⁺ concentration, pH, and immersion time of 10 g/L, 6 and 300 s, respectively. Morphology and surface composition analysis proved that two separate layers of conversion coating containing zirconium, zinc, and nickel oxide/hydroxide compounds were formed in the case samples that were treated by separate solutions. This led to better uniformity and higher thickness of the coating. Finally, adhesion strength of epoxy organic coating on galvanized steel with and without conversion coating was investigated by pull-off measurement. Zr–Ni conversion coating in optimum conditions had a positive effect on adhesion of organic coating in comparison with blank sample and samples pretreated with Zr and Zr + Ni conversion coatings through increased surface roughness and physical interlocking.     

Investigation of fluoacid based conversion coatings on aluminum

Conversion coatings on metals enhance paint or lacquer adhesion and promote corrosion resistance. Traditionally, these conversion coatings were based on chromium chemistry. In recent years, formulations based on fluotitanic or fluozirconic acid and polymer have demonstrated performance on a par with chromium-based treatments. The choice of fluoacid and polymer in the treatment has a strong impact on coating performance. The impact of pretreatment composition was demonstrated for aluminum extrusion processes. Electrochemical investigation, including linear polarization and electrochemical impedance spectroscopy, was used to differentiate corrosion resistance among the various treatments. Scanning electron microscopy, grazing angle infrared spectroscopy, and X-ray photoelectron spectroscopy were used to elucidate chemical composition of the treated aluminum surfaces.     

Electrochemical,SEM and XPS investigations on phosphoric acid treated surgical grade type 316L SS for biomedical applications

A simple surface pre-treatment method was attempted to establish a stable passive layer on the surface of surgical grade stainless steel (SS) of type 316L for biomedical applications. Surgical grade type 316L SS specimens were subjected to H₃PO₄ treatment for 1 h by completely immersing them in the acid solutions to develop a passive barrier film. The effect of various concentrations of phosphoric acid on the localized corrosion resistance behavior of type 316L SS was investigated through electrochemical techniques using cyclic polarization studies and electrochemical impedance spectroscopy (EIS). X-ray photoelectron spectroscopy (XPS) was used to evaluate the nature and composition of the passive films. The surface morphology and relative elemental composition of the untreated and acid treated surfaces subjected to anodic polarization was studied by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDAX) techniques, respectively. Compared with untreated (pristine) 316L SS, the 40% acid treated surface formed a stable passive layer that had superior corrosion resistance.     

Corrosion protection of AISI 316 stainless steel by ALD alumina/titania nanometric coatings

Stainless steels are used today in a wide range of applications as a result of their combination of high corrosion resistance and good mechanical properties. In some applications, for example, temporary contact biomedical devices or solar water heaters, corrosion resistance may need further improvement, and surface coatings may be applied for enhanced protection. In this study, AISI 316 stainless steel samples with two different standard industrial finishes were coated using atomic layer deposition (ALD) of Al₂O₃/TiO₂ layers. The morphology, composition and corrosion protection was then investigated using different techniques. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) were used to obtain a morphological characterization of coatings and substrates. Glow discharge optical emission spectrometry (GDOES) was used to obtain an in-depth profile of composition. Polarization curves in a 0.2 M NaCl solution were used to evaluate the corrosion protection given by the coatings. The deposited ALD layers were found to be almost flawless. The measured RMS roughness values were compared before and after the ALD, and were around 50 and 370 nm for the two samples. GDOES profiles were strongly influenced by the roughness of the substrate. The corrosion protection obtained on AISI 316 stainless steel by the application of nanometric coatings proved to be very effective in reducing the passive region current density from 10^?7 to less than 10^?9 A/cm² and increasing the passive region potential interval from 0.8 to 1.3 V before breakdown.     

Enhanced corrosion resistance of A3xx.x/SiCp composites in chloride media by La surface treatments

The influence of silicon carbide particles (SiCp) proportion and matrix composition of aluminium metal matrix composites (A3xx.x/SiCp) modified by lanthanum-based conversion or electrolysis coating was evaluated in 3.5 wt% NaCl aerated solution. The intermetallic compounds were preferentially covered by lanthanum-based conversion coatings obtained by immersion in 50 °C solution of La(III) salt, and the intermetallic compounds, SiCp and aluminium matrix were covered by lanthanum electrolysis treatment. The corrosion process was studied on the basis of gravimetric tests and electrochemical impedance spectroscopy (EIS) during immersion in 3.5 wt% NaCl aerated solution. The composition of both La coating and corrosion products was analyzed before and after accelerated testing, by scanning electron microscopy (SEM), atomic force microscopy (AFM), low-angle X-ray diffraction (XRD) and X-ray photoelectron spectroscopy (XPS) to determine the influence of surface microstructural changes on corrosion behaviour during exposure to the corrosive environment. The corrosion process was more influenced by the concentration of alloy elements in the matrix than by the proportion of SiCp reinforcement. Both lanthanum treated surfaces presented better behaviour to chloride solution corrosion than original composite surfaces without treatment; however, electrolysis afforded a higher degree of protection than the conversion treatment because the coating was more extensive.     

3D, chemical and electrochemical characterization of blasted TI6Al4V surfaces: Its influence on the corrosion behaviour

The blasting process to increase the roughness of the surface of metallic biomaterials is widely used. As a consequence, one can produce a renewed surface with different topography and chemical composition compared to the original one, which can alter the general corrosion behaviour of the samples. With this idea, the aim of this work is not only the topographical and compositional characterization of blasted surfaces of Ti6Al4V alloy but mainly its influence on the corrosion behaviour of these modified surfaces. The surfaces of Ti6Al4V alloys were blasted with SiO₂/ZrO₂ and Al₂O₃ particles of different size in order to obtain different roughnesses. To carry out the microstructural and topographical characterization of the blasted surfaces, the scanning electron microscopy (SEM) coupled with an energy dispersive X-ray (EDX), the contact profilometry method and the 3D characterization by means of stereo-Fe-SEM have been used. By means of stereo-Fe-SEM, the roughness and the real surface area of the rough surfaces have been calculated. The microstructural, topographical and compositional results have been correlated with the corrosion behaviour of the samples immersed in Hank's solution and studied by means of electrochemical impedance spectroscopy (EIS). The blasting process alters topographical and chemically the surface of the samples. These modifications induce to an increase in the capacitance values of the roughened samples due to the prevalence of the effect of electrochemically active areas of Ti6Al4V surface over the effect of the presence of Al₂O₃ and ZrO₂ particles on the blasted surfaces. However, the general corrosion behaviour of the samples is not drastically changed.     

Preparation and corrosion resistance studies of nanometric sol-gel-based CeO2 film with a chromium-free pretreatment on AZ91D magnesium alloy

Magnesium alloy, although valuable, is reactive and requires protection before it can be applied in many fields. In this study, a novel protective environmental-friendly gradient coating was performed on AZ91D magnesium alloy by non-chromate surface treatments, which consisted of phytic acid chemical conversion coating and the sol-gel-based CeO₂ thin film. The surface morphologies, microstructure and composition of the coatings were investigated by scanning electron microscopy (SEM), energy disperse spectroscopy (EDS) and X-ray diffraction (XRD), respectively. The corrosion resistance of the coatings was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) in 3.5 wt.% NaCl solution. The effects of the concentration, layers, temperature of heat treatment of CeO₂ sol on the anti-corrosion properties of the gradient coating for magnesium were also investigated. The results showed that the gradient coating was mainly composed of crystalline CeO₂. According to the results of electrochemical tests, the corrosion resistance of AZ91D magnesium alloy was found to be greatly improved by means of this new environmental-friendly surface treatment.     

Effect of process parameters of plasma electrolytic oxidation on microstructure and corrosion properties of magnesium alloys

In this work, a plasma electrolytic oxidation process was applied to AZ91 and AM50 magnesium alloys and commercially pure magnesium to produce a protective surface layer. The plasma electrolytic oxidation process was carried out in an alkaline phosphate solution with a DC power supply, using relatively high current densities and short treatment times. The influence of some important process parameters such as current density, treatment time and voltage was studied. The layers were characterised by scansion electron microscopy, X-ray diffraction and X-ray photoelectron spectrometry, in order to investigate the effect of the process parameters on the microstructure and chemical composition. The corrosion resistance properties of the obtained layers were investigated by potentiodynamic anodic polarization and electrochemical impedance spectroscopy tests. The current density, applied during the treatment, influenced the morphology and the thickness of the coatings, and, consequently, the corrosion resistance. The corrosion tests evidenced that the layers obtained with plasma electrolytic process provided a good corrosion protection to the magnesium and magnesium alloys.     

Impact of hybrid self-assembled nanophase particle-based sol–gel coatings on the localized corrosion behavior of modified 9Cr–1Mo steel in chloride medium

Corrosion protection coatings were developed based on a hybrid self-assembled nanophase particle process (HSNAP) for the localized corrosion resistance of modified 9Cr–1Mo steel in 0.05 M NaCl solution. The coating sol was prepared using silane-zirconia precursors and a polymeric crosslinking agent. Scanning electron microscopy and X-ray photoelectron spectroscopy were used to study the morphology and composition of the coated specimens, respectively. The thickness of the coatings was determined by a thickness gauge meter and Raman imaging analysis. The corrosion resistance of coated specimens was analyzed using electrochemical impedance spectroscopy, and it was observed that HSNAP-coated specimens showed superior resistance to localized corrosion than the as-received specimens in chloride medium.     

Effect of Atmospheric Plasma Treatment on Carbon Fiber/Epoxy Interfacial Adhesion

In this work the effect of atmospheric plasma treatment on carbon fiber has been studied. The carbon fibers were treated for 1, 3 and 5 min with a He/O₂ dielectric barrier discharge atmospheric pressure plasma. The fiber surface morphology, surface chemical composition and interfacial shear strength between the carbon fiber and epoxy resin were investigated using atomic force microscopy (AFM), X-ray photoelectron spectroscopy (XPS) and the single fiber composite fragmentation test. Compared to untreated carbon fibers, the plasma treated fiber surfaces exhibited surface morphological and surface composition changes. The fiber surfaces were found to be roughened, the oxygen content on the fiber surfaces increased, and the interfacial shear strength (IFSS) improved after the atmospheric pressure plasma treatment. The fiber strength showed no significant changes after the plasma treatment.     

Corrosion behavior of titania films coated by liquid‐phase deposition on AISI304 stainless steel substrates

Fouling deposition and localized corrosion on the heat‐transfer surfaces of the stainless steel equipments often simultaneously exist, which can introduce additional thermal resistance to heat‐transfer and damage heat‐transfer surfaces. It is a good anticorrosion way to coat a barrier layer of certain materials on the metal surface. In this article, the TiO₂ coatings with nanoscale thicknesses were obtained by liquid‐phase deposition method on the substrates of AISI304 stainless steel (ASS). The coating thickness, surface roughness, surface morphology, crystal phase, and chemical element were characterized with the film thickness measuring instrument, roughmeter, atomic force microscopy, field emission scanning electron microscopy, X‐ray diffraction, and energy‐dispersive X‐ray spectroscopy analyzer, respectively. Corrosion behavior of the TiO₂ coatings was evaluated by potentiodynamic polarization, cyclic voltammograms scanning, and electrochemical impedance spectroscopy tests with the mixed corrosion solution composed of 3.5 wt. % NaCl and 0.05 M NaOH. It is shown that the TiO₂ coating is composed of the nanoparticles with smooth, crack‐free, dense, and uniform surface topography; the roughness of coating surface increases slightly compared with that of the polished ASS substrate. The anatase‐phase TiO₂ coatings are obtained when sintering temperature being varied from 573.15 to 923.15 K and exhibit better anticorrosion behavior compared with ASS surfaces. The corrosion current density decreases and the polarization resistance increases with the increase of the coating thickness. The corrosion resistance of the TiO₂ coatings deteriorates with the increase of the corrosion time. The capacitance and the resistance of the corrosion product layer between the interface of the ASS substrate and the TiO₂ coating are found after the corrosion time of 240 h. A corrosion model was introduced, and a possible new explanation on the anticorrosion mechanisms of the TiO₂ coating was also analyzed. The corrosion mechanism of the TiO₂ coating might comply with the multistage corrosion process. © 2011 American Institute of Chemical Engineers AIChE J, 58: 1907–1920, 2012     

Effect of acidic etching and fluoride treatment on corrosion performance in Mg alloy AZ91D (MgAlZn)

Fluoride activation of Mg AZ91D die-cast alloy surfaces by ammonium fluoride pre-treatment is an important procedure in industry. The procedure forms a fluoride rich layer on the surface enabling the formation of coatings in a uniform manner during further treatments. The present study explores the time dependence of the sequential two-step pre-treatment process – acid etching in H₂SO₄ (first step) and steeping in NH₄F (second step) – on the corrosion properties of AZ91D alloy. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) show the α phase to be selectively etched via a “peeling-off” mechanism that eventually leads to the undercutting and undermining of the β-phase network. After ammonium fluoride treatment, variations in structure and chemical composition of the fluoride rich layer were shown to depend on the underlying phase of the alloy surface by SEM and time-of-flight secondary-ion-mass-spectroscopy (ToF-SIMS). After step 1 (acid etching), electrochemical impedance spectroscopy (EIS) in 3.5% NaCl solution indicates greater charge transfer resistance (R_t) for samples of greater exposed β surface area. This greater R_t increases after step 2 (NH₄F steeping). Furthermore, the corrosion protection properties of F-coated AZ91D can be significantly enhanced by optimizing the durations of the two pre-treatment steps. Indeed, over extension of the duration of either step 1 or step 2 leads to deterioration of the overall corrosion resistance.     

Effect of Iron Slag on the Corrosion Resistance of Soda Lime Silicate Glass

Soda lime silicate glasses containing different amounts of iron slag 0–30 % were prepared. The chemical durability of the prepared glasses was examined by immersion in HCl or HNO₃ solutions at room temperature. The results show that the glass durability increases with increasing the amount of slag in the glass composition to a certain amount, then followed by a decrease in the glass durability. Various mechanisms of corrosion and the role of the mobility of cations and their leaching into solution, also the effect of time of leaching are discussed. The densities of all glass compositions were measured. The quantitative analysis obtained from infrared absorption spectra in the range of (400–4000) cm^?1 in relation to the effect of corrosion on the absorption spectra has been studied in terms of structural concepts. The topography of the glass surfaces was observed by scanning electron microscopy (SEM). The concentration percentage of the ions present on the glass surface was determined by Energy Dispersive X-ray analysis (EDX).     

Development and protection evaluation of two new,advanced ceramic composite thermal spray coatings,Al2O3–40TiO2 and Cr3C2–20NiCr on carbon steel petroleum oil piping

Carbon steel is the most commonly used material in the petroleum industry owing to its high performance and relatively low cost compared with highly alloyed materials. The corrosion resistance of carbon steel in aqueous solutions is dependent on the surface layer created on carbon steel. This layer often consists of siderite (FeCO₃) and cementite (Fe₃C), but it is neither compact nor dense. To improve the carbon steel surface resistance against corrosion and wear, a compact and dense layer can be deposited onto the surface by thermal spray coating. In this research, Al₂O₃–40TiO₂ and Cr₃C₂–20NiCr were deposited onto mechanical part surfaces by HVOF spray technique. The present study describes and compares the electrochemical behavior of carbon steel, Cr₃C₂–20NiCr and Al₂O₃–40TiO₂ in 3.5% NaCl using open-circuit potential measurement (OCP) and electrochemical impedance microscopy (EIS) for 36 days. The tribological and mechanical properties are also investigated using a tribometer (pin-on-disc). The results indicate that these chemical composition coatings facilitated significant anti-corrosion and anti-wear improvement. However, the samples coated with Al₂O₃–40TiO₂ exhibited the lowest corrosion rate. In terms of wear performance, both coated samples displayed similar behavior under different loads. Scanning electron microscopy (SEM) showed the distinctive microstructure of the HVOF-sprayed samples before and after corrosion and wear testing.     

Corrosion resistance and infrared emissivity properties of EPDM (EPDM-g-MAH) film on low infrared emissivity PU/Cu coating

In order to improve the corrosion resistance of low infrared emissivity polyurethane (PU)/Cu coating, ethylene-propylene-diene monomer (EPDM) and maleic anhydride grafted EPDM (EPDM-g-MAH) were deposited on PU/Cu coating by spin coating, respectively. The ability of EPDM and EPDM-g-MAH to serve as corrosion protective films for PU/Cu coating was examined by evolved emissivity immersion test and potentiodynamic polarization measurements in 3.5% NaCl solution. And the chemical composition and surface morphology of PU/Cu coating before and after corrosion were characterized by Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD) and scanning electron microscopy (SEM). The results showed that all of the coated samples present a better corrosion resistance than bare PU/Cu coating due to indissolubility of Cu by aggressive ions, and the effect of EPDM-g-MAH is better than that of EPDM.     

Mica/polypyrrole (doped) composite containing coatings for the corrosion protection of cold rolled steel

Micas/polypyrroles (PPys) doped with molybdate, p-toluene sulfonate, dodecyl benzene sulfonate, and 2-naphthalene sulfonate composite pigments were synthesized by chemical oxidative polymerization and characterized in coatings for corrosion protection on cold rolled steel substrate by various electrochemical techniques. Synthesized composite pigments were characterized for morphology by scanning electron microscopy, which indicated physical formation of PPy on the surface of mica. Chemical composition of the composite pigments was analyzed by X-ray photoelectron spectroscopy which chemically confirmed doped PPy formation on the mica surface. Coatings were formulated at 20% pigment volume concentration (composite pigments or as-received mica pigment) and were applied on cold rolled steel substrate. Coatings were exposed to salt spray test conditions (ASTM B117) for 30 days and were periodically assessed for corrosion with electrochemical impedance spectroscopy (EIS), open circuit potential (OCP), and potentiodynamic polarization. EIS and circuit modeling results demonstrated higher coating resistance (R _c) for mica/PPy (doped) composite coatings as compared to as-received mica pigment containing coating after 30 days of salt spray exposure. Lower current density and more positive corrosion potential values were observed for mica/PPy (doped) composite coatings as compared to mica pigment-based coating in potentiodynamic polarization measurements, indicating improved corrosion protection for cold rolled steel substrate. OCP measurements revealed more positive values for mica/PPy (doped) composite coatings as compared to mica pigment-based coating suggesting superior corrosion protection for mica/PPy (doped) composites.     

热浸镀锌层表面钛盐转化膜研究

利用钛盐成膜工艺在热镀锌层表面获得了色泽光亮、耐蚀性能优良的银白色转化膜层。采用扫描电镜、能谱仪、电化学极化和盐水浸泡方法研究了钛盐转化膜层的表面形貌、元素组成和耐蚀性能。分析了钛盐溶液成分及工艺参数对热镀锌层表面转化膜的耐蚀性能影响。确定的最佳工艺条件为:Ti(SO4)21g/L,H2O260mL/L,pH0.5～1.0,处理温度25～30°C,处理时间10min。热镀锌层经此工艺处理后,耐蚀性能明显提高。     

脉冲电沉积纳米镍-碳化硅复合镀层的性能

分别采用直流(DC)和换向脉冲电流(PRC)电沉积法制得纳米Ni-SiC复合镀层。采用X射线衍射仪、扫描电镜、能谱仪对比研究了纯Ni镀层和Ni-SiC复合镀层的微观结构、宏观残余应力、表面形貌及成分。用浸泡法研究了不同镀层在3.5%(质量分数)NaCl和10%(体积分数)H2SO4溶液中的腐蚀行为。结果表明,脉冲电沉积能改变镀层的微观结构,有效提高镀层硬度,降低宏观残余应力。脉冲电沉积所得到的纯Ni镀层和纳米Ni-SiC复合镀层在3.5%NaCl及10%H2SO4溶液中的耐蚀性均优于直流镀层。脉冲镀层在3.5%NaCl溶液中受腐蚀很轻,主要腐蚀形态为点蚀,而在10%H2SO4溶液中,SiC粒子作为增强相使镀层的耐腐蚀性进一步提高。     

Multifunctional,environmental coatings on AA2024 by combining anodization with sol-gel process

The present work proposes the development of multifunctional composite coatings on AA 2024 by combining anodization and sol-gel process. To render the surface of AA 2024 with maximum corrosion resistance, eco-friendly citric-sulfuric acid (CSA) electrolyte with low sulphur content was used for anodization at 20 V for a duration of 30 min. The obtained anodized layer was porous. Ambient curable hybrid sol-gel coating with 8-hydroxy quinoline (8-HQ) as corrosion inhibitor was used as a sealant for the porous anodized layer to enhance the corrosion resistance with self-healing properties. Surface pre-treatments were carried out using sand blasting and alkaline etching to ensure high surface activity prior to anodization. The surface morphology and chemical composition of samples with and without coatings were characterized by field emission scanning electron microscopy (FESEM) and energy dispersive X-ray spectroscopic analysis (EDX). Adhesion strength and wettability of the coatings were measured by tape adhesion test and water contact angle analysis respectively, which revealed excellent binding strength and hydrophobic nature. The corrosion resistance of the coatings was evaluated using electrochemical impedance spectroscopic (EIS), potentiodynamic polarization and salt spray tests. The results revealed improved corrosion resistance of anodized + 8-HQ sealed AA2024. Moreover, when the coated samples were scribed and exposed to the corrosive medium, the SEM/EDX mapping confirmed presence of corrosion inhibitors at the location of the defect, thereby confirming the self-healing property. Hence, the proposed system is a chromium-free, environment friendly multifunctional system exhibiting excellent self-healing corrosion protection and can be a promising substitute for chromic acid anodization.