Novel composite films prepared by sol–gel technology for the corrosion protection of AZ91D magnesium alloy

A novel composite films technology was developed to improve the anticorrosion performance of AZ91D magnesium alloy. The composite films were prepared via sol–gel method which is a simple application procedure within industry. The structure of xerogels and films, morphology of films were analyzed using thermo-gravimetric (TG) and differential thermal analysis (DTA), Fourier transformed infrared spectroscopy (FT-IR), X-ray diffraction (XRD) and scan electron microscopy (SEM). The anticorrosion performance of the sol–gel coated and uncoated samples in 3.5 wt.% NaCl neutral solution had been evaluated by electrochemical tests. The results demonstrated that the composite films “Ce inner film/Mg outer film” exhibited better corrosion resistance.     

Composite anticorrosion coatings for AZ91D magnesium alloy with molybdate conversion coating and silicon sol–gel coatings

This study evaluated the corrosion resistance of AZ91D magnesium alloy coated by composite coatings which consisted of a molybdate conversion coating and three layers of silicon sol–gel coatings. For molybdate conversion treatment, various conditions including the pH of the molybdate baths, immersion time and bath temperature were investigated using electrochemical measurements. The corrosion resistance of the AZ91D magnesium alloy was improved to some extent by the conversion coating with the optimal conversion parameters (7.3 g/L (NH₄)₆Mo₇O₂₄·6H₂O solution with pH 5 for 30 min at 30 °C).     

Electrochemical study of tailored sol–gel thin films as pre-treatment prior to organic coating for AZ91 magnesium alloy

The behaviour/resistance of four optimised sol–gel coating systems (inorganic, hybrid organic–inorganic, containing zirconium ions and containing cerium ions) against corrosion of AZ91 magnesium alloy were studied. The coatings obtained by the sol–gel process were evaluated as autonomous protective coatings as well as a pre-treatment prior to acrylic top coat. The coating obtained from tetramethoxysilane (TMOS) and diethoxydimethylsilane (DEDMS) as precursors and doped with Ce³⁺ was especially effective as pre-treatment for a final acrylic coating. For non-defected coating the impedance modulus has not changed during the time of immersion (7 days) in 0.5 M Na₂SO₄. An inhibition of coating delamination at the defect of the acrylic coating was recorded by means of LEIS.     

Hybrid nanocomposite coating by sol–gel method: a review

The development of environmentally friendly process for pretreatments of metallic substrates is a field of growing research due to the ban against chromates used as protective pretreatments. Among the possible candidates for environmentally friendly pretreatments of aluminum alloys are the silica-based sol–gel coatings. Such coatings are able to form an Si–O–Al conversion layer providing a stable alumina/sol–gel film interface, which inhibits the onset of corrosion. Sol–gel technology offers a wide range of chemical mechanisms and exhibits high potential substitutes for the environmentally unfriendly chromate metal-surface pretreatment. Sol–gel derived organo-silicate hybrid coatings, preloaded with organic corrosion inhibitors, have been developed to provide active corrosion protection when integrity of the coating is compromised. The incorporation of organic corrosion inhibitors into hybrid coatings has been achieved as a result of physical entrapment of the inhibitor within the coating material at the stage of film formation and cross-linking. Sol–gel derived coatings, especially the hybrid films, provide a dense barrier against electrolyte uptake, and offer a wide range of applications as corrosion protective, hydrophilic coatings, hydrophobic anti-reflective coatings, migration barriers against liquid and volatile compounds, antibacterial modification of textiles and water-repellent antistatic textiles. In this paper, the novel applications of the sol–gel derived coatings are presented and discussed.     

Multilayer zirconium titanate thin films prepared by a sol–gel deposition method

Zirconium titanate multilayer thin films were prepared by an aqueous particulate sol–gel process followed by spin coating. The obtained structures were studied by transmission electron microscope, scanning electron microscope, atomic force microscope, and spectroscopic reflection analyses. According to the results, sound thin films up to three layers were developed, accompanied by an increase in thickness and roughness by increasing the number of the layers. It was also found that the coatings consist of globular nanoparticles with an average diameter of 50 nm. Considering the contribution of roughness to biological responses, the optimization of the surface characteristics to meet an optimal performance seems to be a challenging issue, which demands future studies.     

Corrosion protection by zirconia-based thin films deposited by a sol–gel spin coating method

This paper focuses on the structure and corrosion behavior of 316L stainless steel coated by inorganic ZrO₂, hybrid ZrO₂–PMMA, and combined inorganic–hybrid films. The coatings were deposited by a particulate sol–gel spin-coating route, using carboxymethyl cellulose as a nanoparticle dispersant. The electrochemical evaluations were conducted in a simulated body fluid, via potentiodynamic polarization and impedance spectroscopic experiments. According to the results, the hybrid coating presented a better corrosion protection compared to the inorganic coating, due to a lesser density of structural defects. However, the best corrosion resistance was found for a combined coating which consists of an inorganic bottom layer and a hybrid top layer, due to a desirable compromise of good adhesion and low defect density.     

Optical properties of Nb-doped TiO2 thin films prepared by sol–gel method

In this work, we studied optical properties of pure and Nb-doped TiO₂ synthesized using a sol–gel method and deposited as thin films by spin-coating followed by annealing in air at 500 °C for 1 h. The surface elemental composition was derived from X-ray photoelectron spectra, while structure and surface morphology were investigated using X-ray diffraction and atomic force/scanning electron microscopy. Finally, the optical properties were investigated by means of UV–vis spectrophotometry and spectroscopic ellipsometry.The Nb content was determined from XPS measurements to vary between 1.8 and 4.3 at%. The XRD patterns of the deposited thin films, with a maximum thickness of about 56 nm, showed no diffraction peaks. As proven both by microscopy and spectroscopic ellipsometry studies doping TiO₂ with Nb modified the surface morphology of the samples; the grain size is increasing while the surface roughness decreases with the increase in Nb content. This is accompanied by a decrease in the refractive index and an increase of the extinction coefficient.     

Effect of carbon nanotubes on sintering behavior of alumina prepared by sol–gel method

Alumina (Al2O3)/carbon nanotube (CNT) (99/1 by weight) composite was prepared by mixing CNT dispersion with AlCl₃-based gel, followed by high temperature sintering at a temperature up to 1150 °C in argon. Composite alumina precursor showed phase transition order from amorphous to γ-Al₂O₃ after sintered at 900 °C for 2 h, partially to θ-Al₂O₃ after sintered at 1000 °C for 2 h, and then partially to α-Al₂O₃ after sintered at 1150 °C for 2 h. By comparison, control alumina precursor directly transformed from amorphous to α-Al₂O₃ after sintered at a relatively low temperature of 600 °C for 2 h. Composite alumina showed porous structure with pore diameter ranging from 100 nm to 2 µm, whereas control alumina was relatively pore-free. The elevated alumina-crystal phase transition temperatures and the formation of porous structure were ascribed to the presence of CNTs in alumina precursor. The composite alumina sintered at 900 °C for 2 h containing only γ-Al₂O₃ had a BET surface area of 138 m²/g, which was significantly higher than that of control alumina sintered at 1150 °C for 2 h containing only α-Al₂O₃, ~15 m²/g.     

Structural properties and hyperfine interactions in Co–Zn Y-type hexaferrites prepared by sol–gel method

Y-type barium hexaferrites Ba₂Co_2−xZn_xFe₁₂O₂₂ (0.0≤x≤2.0) were prepared using sol–gel method and then sintering at temperatures between 900 and 1100 °C. The properties of the prepared samples were investigated using X-ray diffraction, scanning electron microscopy, and Mössbauer spectroscopy. XRD patterns revealed the presence of a single Y-type hexaferrite phase in the samples sintered at temperatures above 1000 °C. Mössbauer data indicated that Co²⁺ ions occupied octahedral sites in the T blocks, while Zn²⁺ ions were distributed between the two tetrahedral sites. This trend for cationic distribution resulted in weakening the superexchange interactions between spin-up and spin-down sublattices with increasing Zn content, and a consequent reduction in the hyperfine fields in Zn rich compounds.     

Hydrophilization by coating of silylated polyoxazoline using sol–gel process

Hybrid films prepared from TEOS and polyoxazolines (Si–POx–Si) crosslinking agents were coated on different substrates in order to modify their surface properties. The film cohesion and adhesion on substrates were expected through the hydrogen bonding of the polyoxazoline crosslinked network. Low molecular-weight α,ω-unsaturated polyoxazolines (DA-PMOx)s were synthesized by a one step cationic ring-opening polymerization (CROP) of 2-methyl-2-oxazoline (MOx) with a good control over the molecular weight. Based on double thiol-ene coupling (d-TEC) a post-functionalization of DA-PMOx end chains gave in good yield polyoxazoline cross linker (Si–POx–Si). Glass and various polymer substrates (PP, PEI, POM, etc.) were spin coated by the organic–inorganic hybrid films through sol–gel process. AFM, SEM, visible reflectance spectroscopy and contact angle experiments allowed the full characterization of targeted surfaces and demonstrated the efficiency of the polyoxazoline coating.     

Enhanced corrosion resistance of layered double hydroxides/steam coating composite coating prepared by the hydrothermal method on LA43M magnesium–lithium alloy substrates

An excellent anticorrosion Mg–Al layered double hydroxide (LDH) composite coating was successfully fabricated on LA43M magnesium alloy substrates via an in situ steam coating (SC) process and a subsequent hydrothermal treatment at different temperatures. The microstructure, composition and phase formation of the composite coatings were studied via X-ray diffractometer, energy disperse spectroscopy, and scanning electron microscope, respectively. The corrosion resistance of composite coatings was further investigated using electrochemical measurements and corrosion test. The results showed that LDH/SC composite coating has typical nanosheets microstructure, which effectively seal the defects of SC. As the hydrothermal temperature increases, the thickness and density of nanosheets increases, and the corrosion resistance was significantly improved. Especially, the Mg–Al LDH/SC composite coating prepared at 100°C was the most dense and thickness, and exhibited the optimal and long-term anticorrosion resistance in 3.5 wt.% NaCl soultion. It has the lowest I_corr (1.767 × 10⁻⁸ A/cm²), which decreased by three and two orders of magnitude compared with the bare substrate and SC. Furthermore, it can maintain good chemical stability after immersion in the corrosion medium for 192 h and its hydrogen evolution rate (0.00416 mL·cm⁻²·h⁻¹) and weight lost rate (0.00266 mg·cm⁻²·h⁻¹) were the lowest compared with other samples.     

Modification of the glass surface by titanium dioxide films synthesized through the sol–gel method

The glass surface has been modified by titanium dioxide films synthesized using the sol-gel method. The sol-gel synthesis has been optimized by the experimental design with the use of the Latin square method. The film composition has been evaluated using X-ray powder diffraction analysis and optical measurements. The photoinduced hydrophilicity of the modified glass has been investigated.     

Fabrication of inverted zinc oxide photonic crystal using sol–gel solution by spin coating method

Inverted zinc oxide photonic crystal structures were fabricated from polystyrene sphere (PSS) template using the sol–gel solution of ZnO by spin-coating method. It is easily able to control and fabricate the photonic crystal structures using the self-organized PSS with a size of 193 nm. The inverted ZnO photonic crystal structures observed show the (111) tendency of the hexagonal compact arrangement formation. The resulting structures possess the photonic band gaps in the near-ultraviolet range and exhibit an enhanced photoluminescence spectrum. The technology can effectively increase the light output intensity or efficiency for the applications of optoelectronic devices.     

Characterization and X-ray peak broadening analysis in PZT nanoparticles prepared by modified sol–gel method

Lead zirconate titanate nanoparticles (PZT-NPs) were synthesized by a modified sol–gel method and were calcinated at temperatures of 600, 650 and 700 °C. Fourier transform infrared (FTIR), powder X-ray diffraction (XRD) and thermal analysis (TGA/DTA), indicate that single-phase perovskite PZT-NPs are obtained after heat treatment at a temperature of 650 °C. The TEM results obtained from the PZT-NPs confirm that the morphology of the PZT nanoparticles is spherical, with an average diameter size of 17 nm. We also investigated the crystallite development in the nanostructured PZT by X-ray peak broadening analysis. The individual contribution of many small crystallite sizes and lattice strains to the peak broadening in the PZT nanoparticles prepared at different temperatures were studied using Williamson–Hall (W–H) analysis in the range of 2θ = 15–80°.     

Formation and characterization of p-type semiconductor CuCrO2 thin films prepared by a sol–gel method

This study adopted the sol–gel method to synthesize p-type semiconductor CuCrO₂ films and analyzed the effects of an annealing treatment, under a controlled argon atmosphere by changing the temperature and time, on the phase transformation, micro- and nano-structure, composition, and semiconductor properties of thin films. In the Cu–Cr–O phase transformation system, CuO, Cr₂O₃, and CuCr₂O₄ were the intermediate phases of the reaction for forming CuCrO₂: in the metastable state reaction process, the composite phases changed into a single phase, CuCrO₂; in the stable-state reaction process of CuCrO₂, carbon elements of precursors were released and eliminated; and finally the optoelectronic properties of the CuCrO₂ thin film were adjusted and changed. The CuCrO₂ thin film possessed cell- and polygon-like shaped microstructures. The carbon content in the CuCrO₂ film decreased, so the copper, chromium, and oxygen contents increased accordingly. The optical band gap of CuCrO₂ thin film increased from 2.81 eV to 3.05 eV, while the resistivity decreased. The nanoscale crystal was identified which also of the delafossite CuCrO₂ structure. Using the sol–gel method to prepare the CuCrO₂ thin films, an appropriate annealing temperature and time were helpful in forming the single-phase CuCrO₂; the decrease of precursor elements in the thin film could enhance the band gap and the conductivity of the material.     

Study of cation distribution for Cu–Co nanoferrites synthesized by the sol–gel method

Nano sized polycrystalline soft ferrite particles with composition Cu_1−xCo_xFe₂O₄ (x =0.1, 0.3, 0.5, 0.7, 0.9) were synthesized by the sol–gel technique. The existence of well-defined single cubic spinel structure was confirmed in all the samples by X-ray diffraction. The crystallite size found by XRD varied from 14.8 to 34.0 nm. The microstructure was also characterized by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Slight expansion of the unit cell was detected with the increase of Cobalt concentration, which may be attributed due to larger ionic radius of Co²⁺. Lattice parameter ranged from 8.34 Å to 8.37 Å for Co²⁺ from 0.1–0.9. The distribution of cations amongst A- and B-sites of the lattice was estimated by X-ray diffraction by using the R-factor technique. The results showed that both Cu²⁺ and Co²⁺ ions occupy mainly the B-site while Fe³⁺ ions were equally distributed among A- and B-sites. The data obtained from cation distribution analysis was used to determine the magnetic moment for each sample and VSM studies were also carried out to validate these calculations. Magnetic measurements showed that the saturation magnetization (Ms) and coercivity (Hc) increased with increasing cobalt content.     

Re-crystallization of silica-based calcium phosphate glass prepared by sol–gel technique

Bioactive glass (BG) is a potential material for treating dentin hypersensitivity owing to its high solubility. In this study, we synthesized 80S-BG bioactive glass samples using a sol–gel technique and mixed with various hardening agents. The obtained material could be used in human dentinal dentinal tubule occlusions. X-ray diffraction (XRD), scanning electronic microscopy (SEM), and Fourier transform infrared spectroscopy (FTIR) measurements were employed to investigate the physiochemical properties and dentinal dentinal tubule occlusion efficiency by mixing the 80S bioactive glass (80S-BG) with various hardening agents.The major crystallite phase obtained on mixing 80S-BG with phosphoric acid (PA) was Ca(H₂PO₄)₂·H₂O. The mixture of 80S-BG powders and 20, 30, or 40 wt% PA acted as a hardening agent and achieved a dentinal tubule penetration depth of 30.7–62.6 µm.80S-BG on mixing with suitable PA agents exhibited a short reaction time and good operability, making it feasible for use in occluding dentinal tubules. 80S-BG mixed with hardening agents exhibited a greater potential for treating dentin hypersensitivity as compared to the 80S-BG not mixed with any hardening agents.     

Characterization of doped tin dioxide anodes prepared by a sol–gel technique and their application in an SPE-reactor

Anodes for the electrocatalytic oxidation of organic pollutants in water have been prepared by depositing novel Sb-doped SnO₂ material on Ti supports by the sol–gel technique. Surface analysis of the anodes by nuclear microprobe and XPS-measurements confirmed the formation of a doped film on the substrate. Large scale porous titanium electrodes, up to 50 cm², have been coated with doped SnO₂ for a galvanostatic solid polymer electrolyte (SPE) application, resulting in very low voltage across the stack, even without adding supporting electrolytes to the water. Assessment of the cell performance was carried out using N,N-dimethyl-p-nitrosoaniline (RNO) as a spin trap for ·OH-radicals and phenol as a standard organic contaminant. Kinetic studies were done for the formation of the ·OH-radicals.     

Nanostructure silver-doped zinc oxide films coating on glass prepared by sol–gel and photochemical deposition process: Application for removal of mercaptan

Silver-doped zinc oxide (SDZO) films have been grown on glass substrate by a novel combination of sol–gel and photochemical deposition processes (SGPD). The effect of sintering on structural, electrical and optical properties was investigated. The films were characterized by UV–vis absorption spectroscopy (UV–vis), X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray photoelectron spectroscopy (XPS). The result of X-ray photoelectron spectroscopy (XPS) revealed that the binding energy of Ag 3d_5/2 for SDZO shifts remarkably to the lower binding energy compared to the pure metallic Ag due to the interaction between silver and zinc oxide. The XRD spectra of the SDZO films indicate that silver was incorporated in the hexagonal crystal structure of zinc oxide. SEM micrographs show the uniform distribution of spherical grains of about 73 nm grain size for the pure zinc oxide thin films. The results indicated that silver doping photochemical deposition was a feasible method to tune the optical properties of zinc oxide nanostructures. SDZO films coated on glass were applied for the photodegradation of mercaptan in water. SDZO films were applied for degradation of mercaptobenzoxazole which reduced the mercaptan concentration to more than 98%.