Nanodiamond incorporated sol−gel coating for corrosion protection of magnesium alloy

Sol−gel coatings containing various amounts of hydroxylated nanodiamond (HND) particles were applied on the magnesium alloy for corrosion protection. The micrometric defects in the sol−gel coating completely disappeared after adding 0.01, 0.02 and 0.05 wt.% of the HND nanoparticles. The AFM analyses showed that average roughness of the sol−gel film is about 6.7 nm which increases to 16.1 and 20.2 nm after incorporating 0.005 and 0.02 wt.% of the HNDs, respectively. The corrosion resistance of the coatings was tested in Harrison’s solution by means of EIS technique after 15, 30, 60 and 120 min immersion. The corrosion resistance of the sol−gel coating was remarkably enhanced by incorporating different contents of the HNDs and the best result was obtained for 0.01 wt.%. The results of the EIS experiments were confirmed by the potentiodynamic polarization tests. The corrosion resistance enhancement was attributed to the film compactness (due to the chemical interaction with the HNDs), formation of tortuous pathways for diffusion of the corrosive solution, and filling of the defects by the nanoparticles. However, the beneficial effect of the HNDs on the corrosion resistance gradually diminished as the content of nanoparticle was increased. Finally, the micromorphology of the sol−gel nanocomposites was studied after the corrosion tests.     

Glass-like CexOy sol–gel coatings for corrosion protection of aluminium and magnesium alloys

This work reports the preparation of glass-like, environmentally-friendly, cerium-based coatings for active corrosion protection of aluminium and magnesium alloys. It describes the production of cerium sol–gel sols from cerium nitrate and their deposition by immersion and automatic spray onto aluminium and magnesium alloys to produce uniform coatings with amorphous (glass-like) structures (Ce_xO_y). The coatings have been characterised by profilometry, scanning electron microscopy (SEM), spectral ellipsometry and UV–visible, in order to analyse the structure and density of the glass-like cerium coatings as well as their redox ratio Ce⁴⁺/Ce³⁺ as a function of pH and sintering temperature. Finally, electrochemical measurements (EIS) and standard corrosion tests (neutral salt spray, filiform corrosion, immersion–emersion test and adhesion on embossing and T-bend test) have been performed to study the corrosion behaviour of the cerium glass-like coatings on aluminium and magnesium alloys. EIS measurements confirm the healing or blocking of the defects by the corrosion inhibiting species. Excellent corrosion protection is provided by cerium glass-like coatings, satisfying the most demanding industrial requirements.     

Novel multilayer Mg–Al intermetallic coating for corrosion protection of magnesium alloy by molten salts treatment

A novel multilayer Mg–Al intermetallic coating on the magnesium alloy was obtained by AlCl₃–NaCl molten salt bath treatment. The molten salt was treated at 400 °C, which is lower than the treatment temperature of solid diffusion Al powder. The thick Al₁₂Mg₁₇, Al_0.58Mg_0.42 and Al₃Mg₂ multilayer Mg–Al intermetallic coating forms on the magnesium alloy. The corrosion resistance of AZ91D alloy with and without coating by multilayer of Mg-Al intermetallic compound was evaluated by electrochemical impedance spectroscopy measurements in 3.5% (mass fraction) NaCl solution. The polarization resistance value of the multilayer coating on the magnesium alloy by molten salt bath treatment is greater than that of the uncoated one, which is attributed to the homogenously distributed intermetallic phases.     

Comparison of selected inhibitor doped sol–gel coating systems for protection of mild steel

Current legislation around the use of antifouling and anticorrosion coatings has increased the need to find an environment friendly alternative to existing biocide containing pretreatments for steel structures exposed to sea water. Sol–gel technology offers a solution to fouling and corrosion inhibition since sol–gel chemistry lends itself ideally to functionalisation with a variety of components, for example, corrosion inhibitors. In this study, we have utilised the above mentioned approach in order to produce an inhibitor doped sol–gel protective coating on mild steel. The corrosion protection performance of three inhibitors, i.e. SD (Shieldex303), MOLY (Moly-White101ED-PLUS) and ZAPP (Heucophos ZAPP), added individually to a sol–gel, and applied to mild steel Q panels, were evaluated using electrochemical impedance spectroscopy. The inhibitor containing coatings were shown to protect against corrosion of mild steel; the coatings containing the inhibitors Moly and ZAPP were the most effective of the systems tested.

Highlights

? Sol–gel coatings are potential candidate systems for the protection of mild steel substrates.

? Sol–gel chemistry allows a variety of corrosion inhibitors to be incorporated into the sol–gel coating matrix.

? Evaluation of corrosion inhibition efficiency of sol–gel coatings can be assessed using electrochemical impedance spectroscopy (EIS).     

Electrodeposition and corrosion resistance of Ni–P–TiN composite coating on AZ91D magnesium alloy

In order to improve the corrosion resistance and microhardness of AZ91D magnesium alloy, TiN nanoparticles were added to fabricate Ni–P–TiN composite coating by electrodeposition. The surface, cross-section morphology and composition were examined using SEM, EDS and XRD, and the corrosion resistance was checked by electrochemical technology. The results indicate that TiN nanoparticles were doped successfully in the Ni–P matrix after a series of complex pretreatments including activation, zinc immersion and pre-electroplating, which enhances the stability of magnesium alloy in electrolyte and the adhesion between magnesium alloy and composite coating. The microhardness of the Ni–P coating increases dramatically by adding TiN nanoparticles and subsequent heat treatment. The corrosion experimental results indicate that the corrosion resistance of Ni–P–TiN composite coating is much higher than that of uncoated AZ91D magnesium alloy and similar with Ni–P coating in short immersion time. However, TiN nanoparticles play a significant role in long-term corrosion resistance of composite coatings.     

Polyindole top coat on TiO2 sol–gel films for corrosion protection of steel

The protection efficiency of polyindole film on stainless steel was enhanced via titanium dioxide pre-coating. The characterization of coatings was achieved by nuclear magnetic resonance and Fourier-transform infrared spectra. The surface morphology of electrodes was monitored with scanning electron microscope. The corrosion performance was investigated in 3.5% NaCl solution by electrochemical impedance spectroscopy and potentiodynamic measurements. The quantum calculations were employed, and theoretical parameters were determined. Results showed that the correlation between experimental and theoretical parameters. The high protection efficiency was observed against corrosion on the steel surface via forming a protective polyindole top coated titanium dioxide film.     

Corrosion and high-temperature oxidation of AM60 magnesium alloy

The corrosion and high-temperature oxidation characteristics of AM60 Mg alloy in different environments were investigated by immersion test, electrochemical polarizing analysis and differential thermal analysis （DTA）/thermo gravimetric （TG） experiments. The influence of aging heat treatment on the corrosion resistance of AM60 Mg alloy was studied. AM60 Mg alloy shows better corrosion resistance in sea water than in 3.5%（mass fraction） NaCI solution. The corrosion resistance after aging for 24 h is better than that of both as-cast and aging for 48 h. Corrosion resistance of Mg alloy is controlled by microstructure, composition of a-matrix. Precipitation offl phase along the grain boundaries acts as a barrier that decreases corrosion rate, whereas the decrease of aluminum content of a phase causes an increase in the corrosion rate. The DTA and TG curves of heating process in air are characterized with combustion after 590℃. When heated in helium, the curves show two endothermic peaks and a remarkable evaporation of magnesium. As for isothermal DTA and TG experiments, mass increment caused by oxidation does not happen till 520 ℃.     

Designing for the cerium-based conversion coating with excellent corrosion resistance on Mg–4Y–2Al magnesium alloy

The cerium salt chemical conversion baths containing KMnO₄ are applied to prepare protective coatings on the WA42 alloy surface, and the effect of the concentration of KMnO₄ on the microstructure and corrosion properties of the coatings is investigated by scanning electron microscopy, X-ray photoelectron spectroscopy, and electrochemical tests. The results indicate that with the addition of KMnO₄ to the conversion bath, the microstructure of the coating is more uniform and denser, and the coating with the KMnO₄ concentration of 4 g/L (4M coating) has the most uniform microstructure with the least microcracks. The 4M coating exhibits a two-layered structure, and it is mainly composed of MgO, Mg(OH)₂, CeO₂, Ce₂O₃, Ce(OH)₃, MnO, and MnO₂. In addition, as the KMnO₄ concentration increases from 0 to 6 g/L, the I_corr of the coatings in 3.5% NaCl solution decreases first and then increases, and the 4M coating shows the best corrosion resistance, which should attribute to the uniform and dense microstructure.     

Ceramic nanocomposites obtained by sol–gel coating of submicron powders

MgAl₂O₄–ZrO₂ nanocomposites were fabricated by conventional sintering of composite powders obtained by sol–gel coating of a submicron spinel powder. In the composite powder the zirconia grains remain narrow sized and completely tetragonal even after being heat treated at temperatures where a free xerogel is completely monoclinic. The sintered material exhibits a dense, fine and highly homogeneous microstructure. The zirconia nanoparticles are located at both inter- and intragranular positions and exhibit heteroepitaxial relationships with the surrounding crystals. Tetragonal zirconia seems to be stabilised by an interface effect. Both the scale of the microstructure and the fraction of intragranular grains were controlled by adjusting the mean grain size of spinel grains before coating and sintering conditions.     

Bioactivity,in-vitro corrosion behavior,and antibacterial activity of silver–zeolites doped hydroxyapatite coating on magnesium alloy

Mg-based alloys received significant attention for temporary implant applications while, their applications have been limited by high degradation rate. Therefore, silver–zeolite doped hydroxyapatite (Ag-Zeo-HAp) coating was synthesized on TiO₂-coated Mg alloy by physical vapour deposition (PVD) assisted electrodeposition technique to decrease the degradation rate of Mg alloy. X-ray diffraction (XRD) analysis and field emission scanning electron microscopy (FE-SEM) images showed the formation of a uniform and compact layer of Ag-Zeo-HAp with a thickness of 15 μm on the TiO₂ film with a thickness of 1 μm. The potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) tests indicated that corrosion resistance of Mg-Ca alloy was considerably increased by the Ag-Zeo-HAp coating. The bioactivity test in the simulated body fluid (SBF) solution showed that a dense and homogeneous bonelike apatite layer was formed on the Ag-Zeo-HAp surface after 14 d. Investigation of antibacterial activity via disk diffusion and spread plate methods showed that the Ag-Zeo-HAp coating had a significantly larger inhibition zone (3.86 mm) towards Escherichia coli (E. coli) compared with the TiO₂-coated Mg alloy (2.61 mm). The Ag-Zeo-HAp coating showed high antibacterial performance, good bioactivity, and high corrosion resistance which make it a perfect coating material for biomedical applications.     

Influence of pickling time on electroless Ni–P coating on magnesium alloy

In this study, a simple pickling process in H₃PO₄ and NH₄HF₂ solution was used for electroless Ni–P plating on AZ61 magnesium alloy. It is found that the corrosion rate of magnesium alloy during pickling significantly decreased because NH₄HF₂ was added into H₃PO₄ pickling solution. Ni–P coating plated only with pickling process shows poor adhesion because of the low F/O ratio of the substrate surface. However, F/O ratio, adhesion, and corrosion resistance of Ni–P coating are obviously enhanced after pickling followed by activation. The optimal pretreatment process is pickling for 120 s and activation for 4 min, under which the Ni–P coating has an optimum F/O ratio of 1.8 and the coating gets a dense structure, better adhesion, and higher corrosion resistance.     

Preparation and performance of fluorescent sensing coating for monitoring corrosion of Al alloy 2024

A kind of fluorescent sensing coating was prepared for monitoring corrosion of aluminum alloys by incorporating phenylfluorone（PF） into acrylic paint as sensing material. The fluorescent dye PF reacts with aluminum ions on corroded aluminum substrate to occur fluorescence quenching observed in UV light. This paint system is sensitive tO underlying corrosion processes through reacting with the Al^3＋ produced by anodic reaction accompanying corrosion. After a certain time, when the samples of Al alloy 2024 coated with PF-acrylic paint were immersed in 1 mol/L NaCl solution, fluorescence quenching spots can be seen with unaided eyes. With the development of corrosion process, the size of fluorescence quenching spots increases. Active corrosion areas on the sample surface were found under the fluorescence quenching spots by optical microscope. The corrosion areas can be observed more clearly by SEM, and many pits are found. This suggests that the fluorescence quenching spots are the sites of produced Al^3＋ by the anodic reaction of the local attack of the coated Al alloy substrate in the chloride solution and the corrosion process of the coated AI alloy can be monitored on-line by the sensing coating. The sensitivity of this coating system for detection of anodic reaction associated with corrosion was determined by applying constant charge current and measuring the charge, at which fluorescence quenching is detected in the coating with unaided eyes. Visual observation of coated samples can detect fluorescence change resulting from a charge corresponding to an equivalent hemispherical pit with approximate depth of 50 μn.     

Investigation of high concentration of benzotriazole on corrosion behaviour of titania–benzotriazole hybrid nanostructured coating applied on Al 7075 by the sol–gel method

Nowadays, surface modification with self-healing ability is a valuable technique to improve chemical stability, oxidation behaviour and corrosion resistance of materials without interference with its physical, chemical or mechanical properties of bulk material underneath. In this paper, hybrid organic amorphous titania coatings are deposited on 7075 aluminium alloy substrates by using the sol–gel method. A titania–benzotriazole (BTA) nanostructured hybrid sol–gel coating is impregnated with three different high concentrations of BTA, 1.4, 2.8 and 4.2%. The bonds existing in the hybrid coating, structure and morphology and coating corrosion behaviour have been studied using the FTIR, GIXRD, field emission scanning electron microscopy and electrochemical impedance spectroscopy (EIS) test in a 3.5?wt-% NaCl solution during different immersion times, 24, 48, 72, 96 and 120?h. EIS studies indicated that a higher coating resistance value was gained for titania–4.2% BTA even after 120?h of immersion and BTA acted mainly on the amorphous titania coating as a corrosion inhibitor and a healing agent that acts by two mechanisms: first, release of a healing agent to the formation of corrosion products, then finally blocking surface defects; second, release of a healing agent during 48?h of immersion and its adsorption to produce an insulating layer on the surface of the coating in contact with the solution.     

Enhanced corrosion resistance of micro-arc oxidation coated magnesium alloy by superhydrophobic Mg−Al layered double hydroxide coating

To further enhance the corrosion resistance of the porous micro-arc oxidation (MAO) ceramic layers on AZ31 magnesium alloy, superhydrophobic Mg−Al layered double hydroxide (LDH) coating was fabricated on MAO-coated AZ31 alloy by using in-situ growth method followed by surface modification with stearic acid. The characteristics of different coatings were investigated by XRD, SEM and EDS. The effect of the hydrothermal treatment time on the formation of the LDH coatings was studied. The results demonstrated that the micro-pores and cracks of MAO coating were gradually sealed via in-situ growing LDH with prolonging hydrothermal treating time. Electrochemical measurement displayed that the lowest corrosion current density, the most positive corrosion potential and the highest impedance modulus were observed for superhydrophobic LDH/MAO coating compared with those of MAO coating and LDH/MAO coating. Immersion experiment proved that the superhydrophobic LDH/MAO coating with the active anti-corrosion capability significantly enhanced the long-term corrosion protection for MAO coated alloy.     

Evaluation of corrosion inhibition performance of silica sol–gel layers deposited on galvanised steel

The present work reports a comparative investigation of the electrochemical behaviour of some new types of silica sol–gel coatings with enhanced corrosion resistance deposited on electrolytically or thermally (hot-dip) zinc-coated steel. The coatings were rendered hydrophobic by silylation. Dichlorodimethylsilane or trimethylchlorosilane were used as silylating agents and cetyltrimethylammonium bromide or Pluronic PE 10300, as templating agents. The morpho-structural and optical properties of compact and mesoporous silica coatings were characterised with different methods. The corrosion behaviour of the coatings was evaluated by open circuit potential measurements, Tafel interpretation of the polarisation curves and electrochemical impedance spectroscopy. Both silylating agents improve significantly the corrosion resistance of both porous and compact coatings by reducing the corrosion current density with at least one order of magnitude. The possibility to use the porous structure of the coatings as corrosion inhibitor carriers was explored by loading of mesoporous silica layers with 1H-benzotriazole.     

Galvanic corrosion of Ni–Cu–Al composite coating and its anti-fouling property for metal pipeline in simulated geothermal water

A novel anti-fouling epoxy-silicone composite coating containing Ni–Cu–Al alloy powder for metal pipeline in geothermal water was fabricated based on the basic principles of galvanic corrosion. Fouling behaviors of the surface of composite coating in the simulated geothermal water were studied in comparison with stainless steel and epoxy-silicone resin coating. The results indicated that composite coating possessed a good anti-fouling performance. In the geothermal water, Ni²⁺, Cu²⁺ and Al³⁺ ions, originated from interface electrochemical corrosion, were released into bulk solution. These metal ions intensively inhibited nucleation and crystal growth rate of CaCO₃ fouling on the surface of composite coating, and promoted precipitation of CaCO₃ fouling in the bulk-solution, which could be easily washed away by flowing water. But for 304 stainless-steel and epoxy-silicone resin coating, CaCO₃ fouling grew easily and adhered firmly to their surfaces, and influenced the transport efficiency of geothermal water for pipelines.     

Generation of nanocrystalline NiO particles by solution combustion method and its Zn?NiO composite coating for corrosion protection

The nanocrystalline nickel oxide (NiO) particles have been successfully prepared by a simple, fast, economical, and eco‐friendly solution‐combustion method using Ni(NO₃)₂ · 6H₂O (oxidizer) and sugar (dextrose as fuel). The as‐prepared compound was calcined for an hour at different temperatures. The synthesized NiO was characterized by XRD, TGA, SEM/EDX, TEM, XPS, FT‐IR, and UV–Vis spectral methods. The crystallite sizes of the NiO particles were measured. Rietveld refinement of X‐ray data matches the cubic structure with space group of Fm3m (No. 225). The thermal behavior of as‐prepared compound was examined. Scanning electron micrographs show uniform cubic like morphology of NiO and its chemical composition was measured. The TEM results reveal that the particle sizes were in the order of 70–80 nm. The red shift was noticed in UV–Vis absorption spectra. As an application part the Zn? NiO composite coating was prepared by electrodeposition method and its corrosion behavior was analyzed by Tafel, impedance and anodic polarization in aggressive medium.     

Wear and corrosion studies of Fe–B–Cr alloy coating on en 24 steel by HVOF thermal spray method

This work investigate the wear behavior of Fe–B–Cr coatings on medium carbon steel (EN24) substrate is used for several automotive parts. The high velocity oxy-fuel (HVOF) method was used to create the new crystalline coating of Fe–B–Cr (composition of 59%Fe–26%B–15%Cr in wt %) on a medium carbon steel substrate (AISI 4340). The characteristics of powder and coating are investigated using scanning electron microscopy (SEM) merged with energy dispersive spectroscopy (EDS), optical microscopy (OM) and thermogravmentric analysis (TGA) which were undertaken in the partial characterization of the coating. The phase contents of both powder and coatings were studied by X-ray diffraction (XRD). The coatings consist of melted and un-melted particles identified in the coatings. Moreover, oxides and micro-cracks were observed at the surface. The mechanical property of the coatings was characterized using a microhardness test. The hardness value increased three times more than the substrate. The coated surface showed lower levels of porosity. Moreover, the electrochemical investigation found Fe–B–Cr coating on medium carbon steel. The corrosion test was carried out in an environment with 0.5 M of NaCl, which showed that the corrosion resistance improved by coating.     

Influences of Si on corrosion of Fe–B alloy in liquid zinc

Abstract

Influences of silicon content on the microstructure and corrosion resistance of a Fe–2·5 wt-%B alloy have been investigated by using scanning electron microscopy, X-ray diffraction and energy dispersive spectroscopy. Si can change the microstructure from hypereutectic to eutectic and furthermore, enhance the corrosion resistance of the alloy in molten zinc. The high corrosion resistance of the alloy was mainly attributed to the eutectic phase increase and solubility of Si in α phase enhancement. The corrosion of these alloys in liquid zinc was controlled by the diffusion mechanism. The reaction products are FeZn_6·67, Fe₅SiB₂ and FeSi. The reaction layer further prevents the diffusion of zinc atoms into the base material and delays the reaction between the substrate and the molten zinc efficiently.     

Preparation and corrosion resistance of titanium–zirconium–cerium based conversion coating on 6061 aluminum alloy

This paper aims to develop a chromium-free chemical conversion coating with good corrosion resistance. A novel chemical conversion coating was prepared on 6061 aluminum alloy by dipping in the treatment solution containing titanium/zirconium based-ions and sodium metaphosphate and cerium nitrate hexahydrate as additives. The morphology and composition of the conversion coatings were observed by scanning electron microscopy and energy dispersive X-ray spectroscopy. The microarea structure of conversion coatings at different formation stages was analyzed by electron probe microanalyzer. The electrochemical polarization curve revealed that the corrosion potential of the conversion coating was −0.577 V and the corrosion current density was 0.1148 μA/cm². The equivalent circuit fitted by AC impedance showed that the film resistance reaches 68,140 Ω. The formation of coating preferentially grows on the Al (Fe) Si intermetallic to form oxides of Ti and Zr; then TiO₂ formed by a higher concentration of Ti⁴⁺ gradually covered ZrO₂. Ce³⁺ could adsorb on the intermetallic compound, the hydrolysis of which causes the local pH of the solution to decrease and promotes the aluminum alloy dissolved.