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.     

Detrimental effect of particle sol-gel coating on the corrosion behavior of A380-SiC composite

In this study, the corrosion susceptibility of aluminum matrix composites reinforced with artificially oxidized SiO₂ and sol-gel Fe/TiO₂ coated silicon carbide particles (SiC_p) has been investigated. Corrosion behavior of the composites, fabricated by the liquid metal infiltration technique, was established in chloride containing alkaline environments by cyclic polarization (CP) and electrochemical impedance spectroscopy (EIS) techniques. It has been found that, sol-gel coating of SiC particles with Fe/TiO₂ has a detrimental effect on the corrosion characteristics of A380-SiC metal matrix composite.     

Anticorrosion properties of polyaniline-coated pigments in organic coatings

Four pigments of various morphology – specularite, α-Fe₂O₃; goethite, α-FeO(OH); talc, (Mg₃(OH)₂(Si₄O₁₀); and graphite, C – without and with polyaniline phosphate coating, were tested for the anticorrosion performance in coatings produced by epoxy binders on iron plates. The corrosion tests were carried out in a condenser chamber with continuous water condensation or humidity with sulfur dioxide, and in a salt mist cabinet. Polyaniline coating of pigments in all cases improved the anticorrosion properties. Graphite coated with polyaniline performed the best among eight systems under investigation. The role of graphite and polyaniline conductivity in the electron transfers associated with corrosion of iron has been proposed.     

Effect of sintering temperatures on corrosion and wear properties of sol-gel alumina coatings on surface pre-treated mild steel

Sol-gel alumina coatings were developed on the surface pre-treated (zinc-phosphated) mild steel substrate and subsequently sintered at 300 °C, 400 °C and 500 °C. The alumina sol was synthesised using aluminium iso-propoxide as a precursor material. FTIR of the boehmite (AlOOH) gel sintered at above-mentioned temperatures was employed to identify the presence of various functional groups. The microstructural features and the phase analysis of the sol-gel coated specimens were carried out using SEM and XRD respectively. The corrosion resistance of the sol-gel alumina coatings was evaluated by electrochemical measurement in 3.5% NaCl solution at room temperature. The abrasive wear behaviour of the sol-gel coated specimens was measured in two body (high stress) conditions. The experimental results revealed that the sol-gel coated specimen sintered at 400 °C has superior wear and corrosion resistance properties as compared to the sol-gel coated specimen sintered at 300 °C. However, the sol-gel coated specimen sintered at 500 °C has exhibited a very poor corrosion and wear resistance properties. Poor performance of the sol-gel coatings sintered at 500 °C could be explained to be due to (i) the presence of numerous cracks (ii) absence of organic groups in the coating.     

Characterization and corrosion resistance of organically modified silicate-NiZn ferrite/polyaniline hybrid coatings on aluminum alloys

Hybrid coatings based on organically modified silicate (Ormosil)-NiZn ferrite/polyaniline (10-30 wt.%) were synthesized through a sol-gel technique. Tetraethylenepentamine, 3-glycidoxypropyltrimethoxysilane, tetraethoxysilane and Ni_0.5Zn_0.5Fe₂O₄/polyaniline were used as precursors for the hybrid coatings. These hybrid films were deposited via spin coating onto an aluminum alloy to improve the corrosion protection. The effects induced by the NiZn ferrite/polyaniline content on the chain dynamics, ferromagnetic behavior and corrosion performances of the coated samples were investigated. The rotating-frame spin-lattice relaxation times and scale of the spin-diffusion path length indicated that the configuration of the hybrid films was highly cross-linked, dense and adhered to the aluminum alloy substrates. The magnetic properties of the resulting hybrids showed super-paramagnetic behavior, such as zero coercive force (coercivity = 0 G) and a low blocking temperatures (45 K). Potentio-dynamic and salt-spray analysis revealed that the hybrid films provided an exceptional barrier and corrosion protection in comparison with untreated aluminum alloy substrates.     

Electrolytic MgO/ZrO2 duplex-layer coating on AZ91D magnesium alloy for corrosion resistance

By a two-step fabrication process of electrolytic deposition and annealing treatment, an MgO/ZrO₂ duplex-layer coating has been prepared on AZ91D magnesium alloy as a protective film against corrosion. Owing to the chemical bonding formed after the condensation of precursory hydroxides, the adhesion strength, thickness and compactness of MgO coating on the substrate are significantly enhanced by the intermediate ZrO₂ layer which prevents the formation of corrosion product Mg₂(OH)₃Cl·4H₂O. As a result, the MgO/ZrO₂ duplex-layer coated specimen reveals relatively high corrosion resistance and superior stability in 3.5 wt% NaCl solution with respect to the MgO single-layer coated specimen.     

Sulphidation/oxidation behaviour of TiAlCr and Al2Au coated Ti45Al8Nb alloy at 750 °C

In this paper, we present the sulphidation/oxidation behaviour of a Ti45Al8Nb (at%) alloy coated with different protective surface films. Two intermetallic coatings are considered; TiAlCr and Al₂Au deposited by physical vapour deposition. The coated alloy was subjected to a H₂/H₂S/H₂O yielding pS₂ - 10⁻¹ Pa and pO₂ - 10⁻¹⁸ Pa potentials at 750 °C for up to 1000 h. The corrosion kinetics were determined by means of discontinuous gravimetry and the as-received and exposed samples were characterised using scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX) and X-ray diffraction analysis (XRD). The materials showed the development of a multilayered structure. In the case of the TiAlCr coated Ti45Al8Nb - base alloy, Al₂O₃, TiO₂ and Cr₂S₃ developed. For the Al₂Au coated Ti45Al8Nb samples an Al₂O₃ scale containing TiO₂ nodules was observed at the surface.     

Preparation and characterisation of aluminium pigments coated with silica for corrosion protection

Aluminium pigments with a layer of silica were prepared by a sol–gel method using tetraethoxysilane as precursor and ethylenediamine as catalyst. Under the optimum conditions, the corrosion protection factor can reach 99.3% and average grain almost remains the same size after coating, indicating that the coated aluminium pigments have excellent chemical stability and good dispersibility. FTIR and EDS analyses demonstrate that a layer of silica coating has been formed on the flaky aluminium particle. SEM, AFM and BET analyses show that a smooth and dense silica coating layer has been formed.     

Chlorinated rubber paints for corrosion prevention of mild steel: A comparison between zinc phosphate and polyaniline pigments

The anticorrosion performance of plasticized chlorinated rubber coated mild steel sheets incorporating polyaniline emeraldine salt or zinc phosphate as active pigments were compared using salt spray and immersion in 3.5% NaCl solution. The results obtained by different electrochemical methods indicate the superiority of polyaniline in comparison with zinc phosphate in terms of corrosion protection. The time of the emergence of the first rust spot in 3.5% NaCl solution for the film containing 1.5 wt% polyaniline reach 960 h, which is six times higher than that of the film without polyaniline. The protective mechanism by zinc phosphate and polyaniline pigments were discussed.     

Correlation of interfacial electrode potential and corrosion resistance of plasma polymer coated galvanized steel. Part 1: Ultra-thin plasma polymer films of varying thickness

Ultra-thin SiO₂-like plasma polymer films were deposited on zinc coated steel. Such films led to a strong inhibition of cathodic and anodic electrochemical reactions and a negative shift in the electrode potential. When the SiO₂-like films are additionally coated with a few micron thick organic film, the resulting interface electrode potential is further shifted cathodically down to −0.8 V_SHE as measured by means of a scanning Kelvin probe. This interface potential is about the same as the free corrosion potential of zinc in a chloride containing electrolyte. Accordingly, the interface proved to be extremely resistant to cathodic de-adhesion processes.     

Corrosion resistance of Al–Cu–Fe alloy powder coated with silica using an ultrasound-assisted sol–gel method

Al–Cu–Fe alloy powder, a high-effective lubrication oil additive, was coated by conventional sol–gel method employing tetraethoxysilane (TEOS) as the precursor for purpose of improving its corrosion resistance. The best condition was obtained according to an orthogonal experiment (L₉(3⁴)). Then, the sol–gel method was modified by employing ultrasound to study the effects of both the ultrasonic power and irradiation time on the coating process. Finally, the coated powder had an high corrosion resistance in the acid media of pH 1. The obtained samples were characterised by FTIR, XRD, SEM and EDS.     

Evaluation of the resistance of mortars coated with silver bearing zeolite to bacterial-induced corrosion

An evaluation of the resistance of mortar specimens coated with silver bearing zeolite to biologically produced sulphate and their antimicrobial characteristics was carried out in this study using Acidothiobacillus thiooxidans. The evaluation was performed based on leaching Ca²⁺ and Si⁴⁺ from the cementitious matrix, rate of bacterial sulphur oxidation, increase in biomass concentration, and acid production. The cumulative concentration of Ca²⁺ leaching were 3.5-folds higher (28.5 mg Ca²⁺/g cement) and 2-folds higher (18 mg Ca²⁺/g cement) in the uncoated and epoxy coated mortar specimens compared to those of zeolite coated specimens (9 mg Ca²⁺/g cement and 8 mg Ca²⁺/g cement for type AC and AK respectively). The cumulative leaching Si⁴⁺ was also 2.6-folds higher in the control mortar specimens (0.65-1.8 mg Si⁴⁺/g cement). Biomass concentration in the control specimens reached 210 mg TSS/L, and that of the zeolites coated mortar specimens was 103 mg TSS/L. The bacterial sulphur oxidation was found to follow the same pattern of the bacterial concentration, 230-270 mg SO₄/g S and 158-182 mg SO₄/g S in the control and zeolite coated mortar specimens, respectively. The resistance of the zeolitic coating was further evidenced by the increase in pH of the control mortar specimens which demonstrated the leaching of Ca (OH)₂ from the cement matrix. The stability of zeolite coated specimens was confirmed by the absence of corrosion products as was examined by FE-SEM and XRPD.     

Characterization and corrosion studies of ceria thin film based on fluorinated AZ91D magnesium alloy

The CeO₂ thin film was prepared via sol-gel method on fluorinated AZ91D magnesium alloy surfaces. The surface morphology, composition and the corrosion resistance of the film were investigated in details using scanning electron microscope, X-ray photoelectron spectroscopy and electrochemical impedance spectroscopy as well as potentiodynamic polarization tests. It was found that small amount of MgO and MgF₂ were encapsulated in CeO₂ thin film. The electrochemical measurement results demonstrated that the CeO₂ thin film on fluorinated AZ91D magnesium alloy could improve the corrosion resistance approximately by two orders of magnitude compared with that of the bare substrate.     

Photogenerated cathode protection properties of nano-sized TiO2/WO3 coating

Nano-sized TiO₂/WO₃ bilayer coatings were prepared on type 304 stainless steel substrate by sol-gel method. The performance of photo-electrochemical and photogenerated cathode protection of the coating was investigated by the electrochemical method. The results show that the bilayer coating with four TiO₂ layers and three WO₃ layers exhibits the highest photo-electrochemical efficiency and the best corrosion resistance property. Type 304 stainless steel with the coating can maintain cathode protection for 6 h in the dark after irradiation by UV illumination for 1 h. In addition, the mechanism of the photogenerated cathode protection for the bilayer coating was also explored.     

Improving the high-temperature oxidation resistance of a β-γ TiAl alloy by a Cr2AlC coating

A Cr₂AlC coating was deposited on a β-γ TiAl alloy. Isothermal oxidation tests at 700 °C and 800 °C, and thermocyclic oxidation at 800 °C were performed in air. The results indicated that serious oxidation occurred on the bare alloy. Thick non-protective oxide scales consisting of mixed TiO₂ + α-Al₂O₃ layers formed on the alloy surface. The coated specimens exhibited much better oxidation behaviour by forming an Al-rich oxide scale on the coating surface during the initial stages of oxidation. This scale acts as diffusion barrier by effectively blocking the ingress of oxygen, and effectively protects the coated alloys from further oxidation.     

The corrosion protection of mild steel by polypyrrole/polyphenol multilayer coating

Electrochemical synthesis of very thin polyphenol (PPhe) film was achieved on polypyrrole coated mild steel electrode (MS/PPy) and a multilayer coating was obtained, cyclic voltammetry technique was used for the synthesis. The corrosion performance of this multilayer coating and single PPy coating were investigated in 0.05 M H₂SO₄ solution by using electrochemical impedance spectroscopy (EIS), anodic polarization curves and open circuit potential (E_ocp)-time curves were used. It was found that the multilayer coating could provide much better protection than the single PPy coating for corrosion of MS for much longer periods and an efficiency of 98.3% was determined for this coating after 340 h exposure time in corrosive medium. It is proposed that the very thin PPhe film coated on top of PPy coating lowered the porosity and improved the barrier effect of the coating significantly.     

Prevention of zinc corrosion in oxygenated 0.5 M NaCl by treatment in a cerium(III) nitrate solution and modification with sodium hexadecanoate

A self-assembled monolayer (SAM) of hexadecanoate ion (C₁₆A⁻) was prepared on a zinc electrode covered with a layer of hydrated cerium(III) oxide Ce₂O₃. The protection of zinc against corrosion was examined for the electrode coated with the Ce₂O₃ layer and the C₁₆A⁻ SAM in an oxygenated 0.5 M NaCl solution. A more positive open-circuit potential of the coated electrode was maintained during immersion in the solution for 4 h than that of the uncoated one and polarization curves showed marked suppression of the anodic process, implying that the layer modified with the SAM acted as a passive film. The protective efficiency of the modified layer was extremely high, more than 99%. The zinc surface coated with the Ce₂O₃ layer and the C₁₆A⁻ SAM was characterized by X-ray photoelectron and FTIR reflection spectroscopies and contact angle measurement with a drop of water.     

Protection of iron against corrosion by coverage with ultrathin two-dimensional polymer films of a hydroxymethylbenzene self-assembled monolayer anchored by the formation of a covalent bond

Ultrathin films of two-dimensional polymers were prepared on an iron electrode by modification of a p-hydroxymethylbenzene p-HOCH₂C₆H₄ (HOMB) self-assembled monolayer (SAM) with 1,2-bis(triethoxysilyl)ethane (C₂H₅O)₃Si(CH₂)₂Si(OC₂H₅)₃ (BTESE) and alkyltriethoxysilanes C_nH_2n+1Si(OC₂H₅)₃ (C_nTES, n = 8 and 18). The electrode was derivatized by cathodic reduction of p-hydroxymethylbenzenediazonium tetrafluoroborate HOCH₂C₆H₄N₂BF₄ in an electrolytic acetonitrile solution below 10 °C for 1 h to form the SAM via a covalent bond between carbon and iron atoms. The protective ability of the polymer film against iron corrosion was determined by polarization measurement of the coated electrode in an oxygenated 0.5 M NaCl solution. The protective efficiencies of the polymer films prepared by modification with BTESE plus C₈TES and C₁₈TES were 63.9% and 68.5% after immersion in 0.5 M NaCl for 1.5 h, respectively. These values were higher than those of the one-dimensional polymer films prepared with the respective C_nTES. The film of the HOMB SAM modified with BTESE plus C₈TES was characterized by contact angle measurement using a drop of water and X-ray photoelectron and FTIR reflection spectroscopies. The films of the HOMB SAM modified with BTESE plus C₈TES and C₁₈TES were persistent during immersion of the coated electrodes in 0.5 M NaCl for many hours by far as compared with the alkanethiol SAM anchored on iron by the formation of a coordinate bond.     

The structure and high temperature corrosion performance of medium-thickness aluminide coatings on nickel-based superalloy GTD-111

Simple and Si-modified aluminide coatings having medium-thickness (40-60 μm) have been applied on the superalloy GTD-111 by a slurry technique. Hot corrosion and cyclic oxidation performance of the uncoated and the coated superalloy were investigated by exposing samples to a molten film of Na₂SO₄-40 %wt NaVO₃-10%wt NaCl at 780 °C and 1 h cyclic oxidation at 1100 °C in air, respectively. The presence of silicon in the aluminide structure increased the oxidation resistance by a factor of 1.7 times. In addition, a SiO₂-containing scale, which formed on the Si-containing coating surface, was stable during of the hot corrosion testing.     

Corrosion behaviour in alkaline medium of zinc phosphate coated steel obtained by cathodic electrochemical treatment

The present work evaluated the ability of zinc phosphate coating, obtained by cathodic electrochemical treatment, to protect mild steel rebar against the localized attack generated by chloride ions in alkaline medium. The corrosion behaviour of coated steel was assessed by open circuit potential, potentiodynamic polarization and electrochemical impedance spectroscopy. The chemical composition and the morphology of the coated surfaces were evaluated by X-ray diffraction and scanning electron microscopy. Cathodically phosphated mild steel rebar have been studied in alkaline solution with and without chloride simulating the concrete pore solution. For these conditions, the results showed that the slow dissolution of the coating generates the formation of calcium hydroxyzincate (Ca(Zn(OH)₃)₂·2H₂O). After a long immersion time in alkaline solution with and without Cl⁻, the coating is dense and provides an effective corrosion resistance compared to mild steel rebar.