Addition of carbon black NIR absorber to galvanised steel primer systems: Influence on NIR cure of polyester melamine topcoats and corrosion protection characteristics

Near infrared (NIR) is becoming a popular option for rapid cure of coatings in the coil coating industry particularly where fast line speeds are required. The technology has the potential to reduce the cure time of a 20 μm polyester coating on a galvanised steel substrate from around 30 s via conventional heating methods down to <10 s under the lamps. Previous work suggested that the ideal situation in this case is to have a topcoat which is slightly transparent to NIR and an absorbing substrate to heat the coating from the substrate outwards in a two stage process which separates solvent removal from cross linking and film formation. This can be taken further by tinting the primer layer with a pigment that absorbs in the NIR region. In this study spectroscopy was used to show that a coated steel system could appear white in the visible region because of the reflectance of TiO₂ but the NIR absorption could be altered by adding absorbing pigments such as carbon black. Lamp settings could be reduced by 20% to achieve equivalent cure with tinted primer systems. The potential degradation in corrosion protection afforded by carbon-black containing pigments at various loadings was assessed for model organic coatings applied to galvanised steel specimens. In situ scanning Kelvin probe studies showed that rates of corrosion-driven coating delamination by cathodic disbondment remained unchanged by pigment loadings of up to 3.5 wt%.     

Zinc–magnesium-pigment rich coatings for corrosion protection of aluminum alloys

Chromate (Cr(VI))-based pigments have been widely used for corrosion protective coatings because of their outstanding protection efficiency especially for aluminum alloy products. However, due to environmental issues associated with Cr VI, more and more requests are being made for alternative solutions. In the presented work zinc was modified by alloying with magnesium to achieve a combination of properties – cathodic protection and less reactivity during production, storage and application of the pigments. The magnesium content leads to a lowering of the electrochemical potential which allows the cathodic protection of aluminum alloys. zinc–magnesium pigments were prepared in different compositions with special attention to the intermetallic phases MgZn, Mg₂Zn₃, and MgZn₂. Pigments were produced and a zinc–magnesium rich coating was formulated and compounded. Pickled samples of AA 2024 unclad were coated and the corrosion behavior investigated. A durability of more than 10,000 h in salt spray test could be achieved.     

The spatial distribution of Zn during galvanic corrosion of a Zn/steel couple

The spatial distribution of Zn²⁺ during galvanic corrosion of a model Zn/steel couple in 0.01 M NaCl was investigated using a scanning zinc disk electrode. The couple had a coplanar arrangement of a steel substrate with an electroplated zinc layer at the center. During galvanic corrosion, the marked changes in the Zn²⁺ concentration were confined to a thin solution layer ca. 1.0 mm thick above the couple surface. In this thin solution layer above the zinc layer, a higher concentration region of Zn²⁺ in the range of 5-18 mM extended around the zinc layer in the solution during galvanic corrosion. Conversely, above the steel surface distant from the zinc layer, the surface concentration of Zn²⁺ was almost zero during galvanic corrosion. On this surface, the precipitation of zinc corrosion products due to the hydrolysis reaction of Zn²⁺ was observed. The distribution of the Zn²⁺ concentration supported that Zn²⁺ acted as a buffer that suppressed the increased pH due to the cathodic reaction on the steel surface near the zinc layer and almost no corrosion products formed there. The spatial distribution of Zn²⁺ is discussed in relation to the distributions of potential and pH and the surface morphology of the galvanic couple.     

Synthesis and magnetic properties of Cu-doped ZnO nanowire arrays

Arrays of Cu-doped ZnO nanowires were successfully fabricated by electrodeposition of Zn²⁺ and Cu²⁺ into anodic aluminum oxide template and post-oxidation annealing in air atmosphere. The transmission electron microscopy result shows that the nanowires are uniform, about 100 nm in diameter and with the aspect ratio of up to 40. Selected area electron diffraction and X-ray diffraction results indicate that the nanowires are in hexagonal wurtzite structure. Magnetization measurements show that the Zn_1−xCu_xO (x = 0.07 and 0.11) nanowires exhibit room-temperature ferromagnetism and the enhancement of the ferromagnetism is revealed for the Zn_0.93Cu_0.07O nanowires annealed in vacuum.     

Influence of halides on the dissolution and passivation behavior of AZ91D magnesium alloy in aqueous solutions

The electrochemical behavior of AZ91D in various aqueous sodium halide solutions was investigated using open-circuit potential (E_oc), potentiodynamic polarization and ac impedance (EIS) techniques. Generally, the results reveal that during immersion a protective layer of a salt film is formed on the alloy surface whose passivation performance depends on the halide nature, its concentration and temperature. E_oc shifts positively with time until attaining a steady (E_st) value, which becomes less noble with increasing concentration or temperature of the test solution. At any given conditions, self-passivation was found to be favored in the order F⁻ > I⁻ > Br⁻ > Cl⁻. This sequence is consistent with that for surface film resistance (R_T) and its relative thickness (1/C_T). Nevertheless, in F⁻ medium each of the above parameters increases with [F⁻] up to a critical value of 0.3 M then decreases. Increasing concentration above 0.3 M induces large change in the microstructure of the outermost layer of the fluorinated extremely protective film and depassivation behavior predominates. In Br⁻ and I⁻ solutions, as well as the lower Cl⁻ concentrations (≤0.01 M), AZ91D exhibits pseudo-passive state over the polarization range from the corrosion potential (E_corr) to the knee point (E_pt) in the anodic scan, at which passivity breakdown occurs with rapid increase in the anodic current and hydrogen gas reaction. At Cl⁻ concentrations >0.01 M the negative difference effect (NDE) occurs under cathodic polarization where E_pt lies negative to E_corr. Addition of F⁻ to the Cl⁻ solution can induce large changes in the behavior of AZ91D. Equal concentration addition (1:1) produces the highest propensity of the surface to form passivating layer that can afford better protection.     

Acceleration and quantitative evaluation of degradation for corrosion protective coatings on buried pipeline: Part I. Development of electrochemical test methods

The electrochemical degradation of polyethylene coated onto SS400 was examined in synthetic groundwater. Electrochemical techniques (electrochemical impedance spectroscopy, potentiodynamic and potentiostatic polarization tests) and surface analysis (scanning electron microscopy) were used to accelerate and evaluate the coating degradation. The pulsed potentiostatic polarization test accelerating both the cathodic reduction and anodic oxidation reactions was applied to reproduce the coating degradation mechanisms of cathodic disbondment and oxide lifting. The applied potentials were determined to be ±300 mV_SCE versus open-circuit potential from the analysis of the anodic and cathodic polarization data. Results from the EIS confirmed that coating degradation is accelerated effectively by the pulsed potentiostatic polarization testing.     

Cathodic disbondment resistance with reactive ethylene terpolymer blends

Adhesion to metallic substrates can be improved through the addition of polar functional groups, which bond with surface groups on the metal substrate. Additionally, polar interactions have been shown to increase adhesive strength even in wet environments (such as in the case for cathodic protection). A polymer blend is proposed as a coating material to provide adequate protection against the diffusion of moisture and air to the metallic surface along with superior adhesion even in the presence of wet and corrosive environments to resist cathodic disbondment. A reactive ethylene terpolymer (RET) of ethylene/n-butyl acrylate/glycidyl methacrylate (E/nBA/GMA) was compounded with HDPE to develop a potential coating material. The HDPE component offers high chemical and moisture resistance to permeation, while the RET component provides the material with high polarity and reactivity, which enhances adhesion to the substrates to be coated. The introduction of the reactive ethylene terpolymer decreases the magnitude of cathodic disbondment area of polyethylene coatings. After applying a cathodic potential to the coating substrate, the adhesive strength was observed to remain the same for silane-pretreated steel dollies. Without silane pretreatment, post-CD adhesive loss resembles that of the open circuit “wet” condition. EDAX data in conjunction with oxygen and water vapor transmission rates suggest an initial stage of disbondment where interfacial oxide is dissolved resulting in the delamination of coating around the initial defect. This initial disbondment zone acts like a moving crack tip creating larger areas of disbondment where interfacial bonds are degraded by the ingress of moisture and ions along the interface.     

Microwave dielectric properties of the (1 − x)Mg2TiO4-xCaTiO3-y wt.% ZnNb2O6 ceramics system

Composite ceramics based on (1 − x)Mg₂TiO₄-xCaTiO₃-y wt.% ZnNb₂O₆ (x = 0.12-0.16, y = 0-8) were prepared by a conventional mixed-oxide route. Zn²⁺ partially replaced Mg²⁺ in Mg₂TiO₄ and formed the spinel-structured (Mg_1−δZn_δ)₂TiO₄ phase. Nb²⁺, is known to be solid soluble in CaTiO₃, was found to change its shape from cubic to pliable. A bi-phase system (Mg_1−δZn_δ)₂TiO₄ and CaTiO₃ exhibited in all samples, where a small amount of second phase Mg_1−δZn_δTiO₃ was also detected. The microwave dielectric properties of specimens were strongly related to ZnNb₂O₆ and CaTiO₃ content. As y increased, ?_r and τ_f decreased, however, Q × f decreased to a minimum value and started to increase thereafter. It was also found that ?_r and τ_f increased and Q × f decreased with increasing x. The optimized microwave dielectric properties with ?_r = 18.37, Q × f = 31,027 GHz (at 6 GHz), and τ_f = 0.51 ppm/°C were achieved for (1 − x)Mg₂TiO₄-xCaTiO₃-y wt.% ZnNb₂O₆ (x = 0.12, y = 4) sintered at 1360 °C for 6 h.     

Electrocrystallisation of zinc from acidic sulphate baths; A nucleation and crystal growth process

The electrochemical nucleation and growth of zinc on low-carbon steel from acidic (pH 2.0-4.5) baths containing ZnSO₄, NaCl, and H₃BO₃, was studied by means of chronoamperometry at various cathodic potentials under a charge-transfer controlled regime. It is shown that at overpotentials in the range 0.30-0.55 V (negative to the Zn²⁺/Zn redox value) the electrodeposition proceeds by instantaneous three-dimensional nucleation, which turns to progressive at higher overpotentials and/or very acidic baths. At low cathodic overpotentials (<0.30 V), a two-dimensional contribution limited by the incorporation of Zn ad-atoms in the developing lattice becomes significant at the early stages of deposition, and is more progressive in type the more acidic is the bath pH. Nucleation rate constants were calculated and correlated analytically with the respective potentials, using the classical theory of heterogeneous nucleation, which though fails to lead to reasonable values for the critical nucleus size.     

Templated growth of cadmium zinc telluride (CZT) nanowires using pulsed-potentials in hot non-aqueous solution

A single step non-aqueous electrodeposition of cadmium zinc telluride (CZT) nanowires on nanoporous TiO₂ substrate was investigated under pulsed-potential conditions. Propylene carbonate was used as the non-aqueous medium. Cyclic voltammogram studies were carried out to understand the growth mechanism of CZT. EDAX and XRD measurements indicated formation of a compound semiconductor with a stoichiometry of Cd_1−xZn_xTe, where x varied between 0.04 and 0.2. Variation of the pulsed-cathodic potentials could modulate the composition of the CZT. More negative cathodic potentials resulted in increased Zn content. The nanowires showed an electronic band gap of about 1.6 eV. Mott-Schottky analyses indicated p-type semiconductor properties of both as-deposited and annealed CZT materials. Increase in Zn content increased the charge carrier density. Annealing of the deposits resulted in lower charge carrier densities, in the order of 10¹⁵ cm⁻³.     

Structural analysis and characterization of doped spinel Co2−xMxTiO4 (M=Mg2+, Mn2+, Ni2+, Cu2+ and Zn2+) coated mica composite pigments

A new kind of composite mica pigments were prepared by coating Co_2−xM_xTiO₄ composite oxide nanoparticles onto mica, to investigate the effects of doping ions Mg²⁺, Mn²⁺, Ni²⁺, Cu²⁺ and Zn²⁺ on the properties of the doped composite pearlescent pigments, such as the crystal structure, color and shading power. The structure, morphology, color and shading power of the coated pigments were characterized by the X-ray diffraction (XRD), scanning electron microscopy (SEM), UV–vis spectrophotometer and CIE L*a*b* methods. SEM images of coated pigments showed that mica were coated uniformly with a single layer of dispersed nanoparticles. Research of the doped composite pigments showed that the doping ions had entered into the spinel crystal structure, forming a new kind of composite mica pearlescent pigments coated with Co_2−xM_xTiO₄. For the analysis of color and shading power of the pigments, doping of Ni²⁺ and Zn²⁺ can improve the color and shading power of the doped pigments, but the larger dosage of Zn²⁺ doping can weaken the color and shading power of the doped pigments. Doping of Mg²⁺, Mn²⁺ and Cu²⁺ metal ions can also weaken the color and shading power of the doped pigments.     

Electrochemical study on the inhibitory effect of the underpotential deposition of zinc on Zn-Co alloy electrodeposition

Zn-Co alloy electrodeposition from chloride baths containing different Zn²⁺/Co²⁺ ratios was investigated by cyclic voltammetry and anodic linear sweep voltammetry using a Pt electrode. The peaks were attributed by means of EDX analysis, SEM and TEM observations performed on some alloys potentiostatically deposited. In the range of potential where zinc deposits underpotential, cyclic voltammetry showed a complex cathodic peak with one maximum and two shoulders, correlated with the deposition of different cobalt rich alloys. Up to four anodic peaks, two correlated with zinc oxidation from η and γ phases and two correlated with oxidation of solid solutions of zinc in cobalt, were observed. ALSV and TEM indicated that the remarkable increase in Zn content of the alloy, which occurs with a strong inhibition of the process at potentials more negative than that of the cathodic peak and more positive than the bulk deposition potential of zinc, is due to the deposition of γ phase. No inhibition of the alloy deposition process was observed with very low concentrations of zinc (<0.015 M) in the bath containing 0.19 M Co²⁺.     

Corrosion protection of steel and bond durability at polyphenylene sulfide-to-anhydrous zinc phosphate interfaces

To enhance the performance of high-temperature polyphenylene sulfide (PPS) coating in protecting steels from corrosion, the cold-rolled steel surfaces were prepared with anhydrous zinc phosphate (Zn · Ph) conversion coatings containing poly(acid) anhydride as an interfacial tailoring material. The factors contributing to the formation of a good bond at the PPS/Zn · Ph joints were as follows: (1) the chemical reaction of PPS with Fe₂O₃ in the Zn · Ph layers, (2) PPS-to-poly(acid) anhydride interaction, and (3) the mechanical interlocking between PPS and the rough Zn · Ph crystal surfaces. Although such interfacial bond structures provide a superior durability of PPS/Zn · Ph joints against a hot H₂SO₄ solution, the cathodic reaction, H₂O + ½O₂ + 2e^? = 2OH^?, occurring at any defect in the PPS/Zn · Ph joint system when NaCl is present will lead to the delamination of the PPS film from the phosphated steel. This cathodic delamination was due mainly to alkali-induced dissolution of Zn · Ph layers. However, the rate of delamination for the PPS/Zn · Ph systems was considerably lower compared with that for the PPS/steel system in the absence of Zn · Ph.     

Factorial experimental design for biosorption of iron and zinc using Typha domingensis phytomass

Typha domingensis phytomass was used as a biosorbent for metal ions removal from wastewater. A full 2³ factorial design of experiments was used to obtain the best conditions of biosorption of Fe³⁺ and Zn²⁺ from water solutions. The three factors considered were temperature, pH, and biosorbent dosage. Two levels for each factor were used; pH (2.5 and 6.0), temperature (25 and 45 °C), and phytomass loading weight (0.5 and 1 g/50 ml). Batch experiments were carried out using 50 ml solutions containing 10 mg/l Fe³⁺ and 4 mg/l Zn²⁺ simulating the concentration of those metals in a real wastewater effluent. The removal percentages of iron and zinc after 120 min of contact time were then evaluated. The results were analyzed statistically using the Minitab 15 statistical software to determine the most important factors affecting the metals removal efficiency. The pH was found to be the most significant factor for the two studied metal ions.     

Characterization of high performance composite coating for the northern pipeline application

High performance composite coating (HPCC) provides a potential, excellent coating alternative for integrity maintenance of pipelines in the northern area. In this work, the physical, chemical and mechanical properties of HPCC were investigated to determine the microstructure, water permeability, cathodic disbondment resistance, electrochemical impedance, adhesion and impact resistance of the coating. It is shown that the addition of polyethylene layer significantly improves the compactness of the coating and enhances its resistance to water and chemical penetration, resulting in a small water vapor transmission rate and permeance. There is a quite small cathodic disbondment of HPCC under the standard test. The impedance characteristic measured on HPCC-coated steel shows a capillary behavior, indicating an effective protection over the underlying steel from corrosion. The adhesion of HPCC to the substrate ranks top one according to both ASTM and CSA standards. The impact energy of HPCC is 9.7 J at 22 °C, and about 10.2 J around 0 °C.     

Linear sweep anodic stripping voltammetry of heavy metals from nitrogen doped tetrahedral amorphous carbon thin films

Nitrogen doped tetrahedral amorphous carbon (ta-C:N) thin films were deposited on p-Si (1 1 1) substrates (1 × 10⁻³ to 6 × 10⁻³ Ω cm) by a filtered cathodic vacuum arc technique with different nitrogen flow rates (3 and 20 sccm). The ta-C:N film coated samples were used as working electrodes to detect trace heavy metals such as zinc (Zn), lead (Pb), copper (Cu) and mercury (Hg) by using linear sweep anodic stripping voltammetry in 0.1 M KCl solutions (pH 1). The influence of nitrogen flow rate on the sensitivity of the films to the metal ions was investigated. The results showed that the current response of the ta-C:N film electrodes was significant to differentiate all the tested trace metal ions (Zn²⁺, Pb²⁺, Cu²⁺, and Hg²⁺) and the three ions (Pb²⁺ + Cu²⁺ + Hg²⁺) could be simultaneously identified with good stripping peak potential separations.     

Biosorption of Zn(II) from Seawater Solution by the Microalgal Biomass of Tetraselmis marina AC16-MESO

Biosorption refers to a physicochemical process where substances are removed from the solution by a biological material (live or dead) via adsorption processes governed by mechanisms such as surface complexation, ion exchange, and precipitation. This study aimed to evaluate the adsorption of Zn²⁺ in seawater using the microalgal biomass of Tetraselmis marina AC16-MESO “in vivo” and “not alive” at different concentrations of Zn²⁺ (0, 5, 10, and 20 mg L⁻¹) at 72 h. Analysis was carried out by using the Langmuir isotherms and by evaluating the autofluorescence from microalgae. The maximum adsorption of Zn²⁺ by the Langmuir model using the Q_max parameter in the living microalgal biomass (Q_max = 0.03051 mg g⁻¹) was more significant than the non-living microalgal biomass of T. marine AC16-MESO (Q_max = 0.02297 mg g⁻¹). Furthermore, a decrease in fluorescence was detected in cells from T. marina AC16-MESO, in the following order: Zn²⁺ (0 < 20 < 5 < 10) mg L⁻¹. Zn²⁺ was adsorbed quickly by living cells from T. marine AC16-MESO compared to the non-living microalgal biomass, with a decrease in photosystem II activities from 0 to 20 mg L⁻¹ Zn²⁺ in living cells.     

Low temperature and microwave dielectric properties of TiO2/ZBS glass composites

TiO₂ based ceramic/glass composites were prepared by a non-reactive liquid phase sintering (NLPS) using zinc borosilicate (ZBS) glass having the deformation temperature of 588 °C. The compounds of Zn₂SiO₄ and Zn₄B₆O₁₃ were formed after the sintering process, indicating that the ZBS glass was a non-reactive one in this system. For TiO₂/50 vol% ZBS glass composite, the two-stage sintering behavior was conducted as the sintering temperature increased. The former might be correlated to the NLPS process and the latter appeared to be related to the crystallization. The dielectric constant (?_r) was mainly affected by the porosity and obeyed the logarithmic mixing rule. The quality factor (Q × f₀) showed an increase and then a steep decrease after the maximum at 850 °C. TiO₂/50 vol% ZBS glass composite sintered at 900 °C demonstrated 36 in the dielectric constant (?_r) and 7500 GHz in the quality factor (Q × f₀) for an application to LTCC filters.     

Current efficiency studies of the zinc electrowinning process on aluminum rotating cylinder electrode (RCE) in sulfuric acid medium: Influence of different additives

This work studies the effect of three additives, sodium lauryl sulfate (SLS), cetyltrimethylammonium bromide (CTABr) and arabic gum (AG) on zinc electrowinning on aluminum in a solution of 85 g L⁻¹ Zn(II) (1.3 M) in 108 g L⁻¹ H₂SO₄ (1.1 M). The influence of these three additives is analyzed during the different stages of the reduction process using chronopotentiometric techniques on an aluminum rotating disk electrode (RDE). Potential ranges (−1.05 < E < −0.85 V versus SHE) and current density (−51 < i < −0.2 mA cm⁻²) within which zinc electrodeposition takes place in the presence of the three different additives were established. These parameters were used to determine current efficiencies (Φ), evaluated by electrolysis on an aluminum rotating cylinder electrode (RCE); the zinc deposition efficiency in the presence of SLS, CTABr and AG, was 95%, 96% and 99%, respectively, were all greater than the efficiency obtained without any additive (WA), Φ = 84%. The homogeneity of the deposits at the end of electrolyses implied that the (RCE) promotes uniform current density on the electrode surface and, hence, can be considered a model cell to evaluate current efficiencies.     

The integral capacitance,kinetics and mechanisms of the Cu/Cu(II) system in sulphuric acid media

Galvanostatic investigation has been carried out on the Cu/Cu(II) system 2 M H₂SO₄ + 0.7 M CuSO₄, at 298 K. The pseudo-capacitance (integral capacitance) has been extracted as a function of overvoltage from the portion of the charging curve prior to plateaux. It has been found that the pseudo-capacitance, for both anodic and cathodic processes depended upon the current density and time. On the basis of the above findings the reaction mechanism has been suggested to be Cu?Cu(I)_ad^v + ve^?, Cu(I)_ad^v?Cu(I) + (1 ? v)e^?, Cu(I)?Cu(II)e^?.