Influence of substrate composition on corrosion protection of sol–gel thin films on magnesium alloys in 0.6 M NaCl aqueous solution

The corrosion protection behaviour of organic–inorganic hybrid thin films on AZ31 and AZ61 magnesium alloy substrates has been studied. These films were prepared by a sol–gel dip-coating method. The organopolysiloxane precursors were γ-methacryloxypropyltrimethoxysilane (MAPTMS) and tetramethoxysilane (TMOS). An attempt was made to determine the possible relationships between the degradation of the sol–gel film and composition of the metal substrate during the exposure of the metal/coating system to 0.6 M NaCl aqueous solutions. For this purpose electrochemical impedance spectroscopy (EIS) and hydrogen evolution measurements were applied. Scanning electron microscopy (SEM), atomic force microscopy (AFM) and X-ray photoelectron spectroscopy (XPS) analyses revealed that the sol–gel films formed on the surface of AZ61 alloy were far more perfect and uniform than those formed on the AZ31 alloy. This behaviour was attributed to the effect of the native oxide film initially present on the surface of the AZ61 alloy, which inhibited the attack of magnesium. Results indicated that the sol–gel coated AZ61 substrate tended to develop corrosion products slower than the sol–gel coated AZ31 substrate, trend that could change by prolonging exposure time. After 6 days of immersion, a clear inhibitive effect of the corrosion products formed during the test was observed in the case of the sol–gel coated AZ31, but not with the coated AZ61 alloy substrate, a phenomenon explained by the carbonate enrichment observed by XPS.     

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.     

Preparation and corrosion protective properties of nanostructured titania-containing hybrid sol–gel coatings on AA2024

Titania-containing organic–inorganic hybrid sol–gel films have been developed as an alternative to chromate-based coatings for surface pretreatment of aluminium alloys. Stable hybrid sols were prepared by hydrolysis of 3-glycidoxypropyltrimethoxysilane and different titanium organic compounds in 2-propanol solution in the presence of small amounts of acidified water. Different diketones were used as complexing agents in this synthesis for controllable hydrolysis of titanium organics. The properties of the obtained coatings were compared with those of zirconia-containing films. Electrochemical impedance spectroscopy (EIS) measurements and standard salt spray tests were performed to investigate the corrosion protection performance of the hybrid coatings. It was revealed that their protective properties depend significantly on the nature of metalorganic precursors and complexing agents used in the process of sol preparation. The best anticorrosive protection of AA2024 in chloride solutions is provided by the titania-containing sol–gel films prepared with titanium(IV) tetrapropoxide and acetylacetone as starting materials. In the case of zirconia-containing films, better protective properties were found when applying ethylacetoacetate as a complexing agent.     

ZrO2 sol–gel pre-treatments doped with cerium nitrate for the corrosion protection of AA6060

Sol–gel coatings represent an alternative corrosion protection method to the chromate based systems which must be replaced. Recently, it was shown that ZrO₂ based sol–gel coatings deposited on AA6060 can provide a good corrosion protection to AA6060. However, ZrO₂ based sol–gel systems are not able to provide the self-healing effect which is instead the peculiar property of chromate conversion coatings. The structure of the ZrO₂ based sol–gel systems does not contain species able to restore the barrier properties when defects or damages impair the coating protection.     

Electrochemical investigation of high-performance silane sol–gel films containing clay nanoparticles

Silane sol–gel coatings are widely used as adhesion promoters between inorganic substrates, such as metals, and organic coatings. The aim of these pre-treatments is to enhance the corrosion protection performance of the organic coating improving the adhesion to the substrate and acting as a barrier against water and aggressive ions diffusion. It is a matter of fact that the silane sol–gel pre-treatments do not provide an active protection against corrosion processes except for the partial inhibition of the cathodic reaction. Inorganic pigments can improve the barrier properties of the silane sol–gel film, enhancing the resistance against corrosion. In this study, different amounts of montmorillonite nanoparticles were added to a water based silanes mixture in order to improve the barrier properties of the sol–gel coating. Hot dip galvanized steel was used as substrate. The sol–gel film consists of a combination of three different silanes, GPS, TEOS and MTES. The clay nanoparticles used in this study were mainly neat montmorillonite. The proper concentration of filler inside the sol–gel films was determined comparing the corrosion resistance of silane layers with different nanoparticles contents. Additionally, the effect of CeO₂ and Ce₂O₃ enriched montmorillonite particles. The EIS analysis and the polarization measurements demonstrated that the optimal amount of neat montmorillonite nanoparticles is about 1000 ppm. The same electrochemical techniques highlighted the limited effect of the cerium oxides grafted to the clay nanoparticles on the corrosion resistance of the silane sol–gel film. The TEM analysis proved the presence of a nano-crystalline structure inside the silane sol–gel film due to the formation of crystalline silica domains.     

The electrochemical behaviour of sol–gel hybrid coatings applied on AA2024-T3 alloy: Effect of the metallic surface treatment

The effect of surface pre-treatments on the electrochemical behaviour of sol–gel coated AA2024-T3 alloys was studied in this work. Three different cleaning procedures were employed: degreasing, mechanical polishing, and chemical etching. The surface morphology was different depending on the pre-treatment. The smoothest surface corresponded to polished samples while the chemically etched ones had the highest roughness, even though the sol–gel film covered all the cavities. The hybrid sol–gel film was prepared by copolymerisation of two different sols, tetra-n-propoxyzirconium (TPOZ) as inorganic precursor and 3-glycydoxypropyltrimethoxysilane (GPTMS) as organic precursor. The corrosion resistance was evaluated using accelerated test (salt spray) and electrochemical measurements under continuous immersion. Both experiments indicated that degreased samples had better anticorrosive properties.     

Corrosion protection evaluation of silica/epoxy hybrid nanocomposite coatings to AA2024

Silica-based organic–inorganic hybrid nanocomposite films have been developed by sol–gel method for corrosion protection of AA2024 alloy. The sol–gel films have been synthesized from 3-glycidoxypropyltrimethoxysilane (GPTMS) and tetraethylorthosilicate (TEOS) precursors. Interlinked organic–inorganic networks can be formed because of the presence of both epoxy and silicon alkoxide functionalities in the precursor molecules. In order to investigate the effective factors on the properties of organically modified silicates films (Ormosils), different coatings with different organic and hydrolysis water content were developed. The films were prepared by dip-coating technique. The chemical composition and the structure of the hybrid sol–gel films were studied by energy dispersive spectroscopy (EDS) and scanning electron microscopy (SEM), respectively. The corrosion protection properties of the films were studied by potentiodynamic scanning (PDS) and salt spray tests. The results indicate that the hybrid films provided exceptional barrier and corrosion protection in comparison with untreated aluminium alloy substrate.     

Corrosion study of hybrid sol–gel coatings containing boehmite nanoparticles loaded with cerium nitrate corrosion inhibitor

To improve the corrosion protection of sol–gel derived hybrid silica/epoxy coatings containing boehmite nanoparticles, inorganic corrosion inhibitor was introduced into the coating via encapsulation in the nanoparticles. The morphology and chemical structure of the deposited films were studied by Scanning Electron Microscopy (SEM) and Fourier Transformed Infra-red Spectroscopy (FT-IR). The anticorrosion and self-healing properties of the coatings were evaluated by Electrochemical Impedance Spectroscopy (EIS). The high corrosion resistance performance of such coatings is due to the presence of encapsulated cerium nitrate corrosion inhibitor that can be released at the defects within the coating, hindering the corrosion reactions at defective sites.     

Effect of the experimental setup in the behaviour of sol–gel coatings

Electrochemical behaviour of the sol–gel-coated AA2024-T3 samples was evaluated using electrochemical impedance spectroscopy (EIS) in a three-electrode arrangement cell using Na₂SO₄ 0.1 M solution as electrolyte. The effect of the reference electrode leakage was examined using as reference a low-leakage Ag/AgCl electrode and a platinum wire. The results show that very low-chloride concentrations in solution are able to induce heavy dissolution of intermetallic precipitates. That corrosion process masks information on the barrier properties of sol–gel coatings otherwise available through EIS measurements.     

Using electrochemical measurements to estimate coating and polymer film durability

Electrochemical measurements are increasingly being used to evaluate the durability of coatings and polymer films in significantly shorter times than those needed to complete long-term exposure tests. Electrochemical measurements have their limitations and nuances. Variability of data, collecting data before samples reach steady state, and misinterpretation of the data can lead to erroneous estimations of coating and polymer film durability. However, replicate samples, monitoring open circuit potential, and capacitance magnitudes can be used to develop more accurate estimations of polymer film, coating, or coated metal durability from electrochemical data. Presented at the 80th Annual Meeting of the Federation of Societies for Coatings Technology, in New Orleans, LA, October 30–November 1, 2002. 510 Charmany Dr., Ste. 55, Madison, WI 53719, rustdr@pairodocspro.com, www.pairodocspro.com.     

Sol–gel processing of hybrid nanocomposite protective coatings using experimental design

Environmentally friendly hybrid nanocomposite sol–gel coatings as substitutes for chromate conversion coatings have attracted a great deal of attention recently. The coatings derived from hydrolysis and condensation of polymerizable silane precursors tetraethylorthosilicate (TEOS) and 3-glycidoxypropyltrimethoxysilane (GPTMS) were deposited onAA5083 substrates by a dip coating technique. Statistical design of experimental (DoE) methodology based on Taguchi orthogonal design has been used to study and optimize compositional and process parameters using multifactor analysis of variance (ANOVA) analysis method and the adhesion strength of coatings to the substrate as per pull off test has been used as a response. Adhesive strength of sol–gel coatings to the substrate was evaluated using pull off and tape tests. Bending, impact resistance and pencil scratch tests were employed to characterize mechanical properties of different coatings. The surface morphology and chemical composition of the hybrid films were studied by atomic force microscopy (AFM) and Attenuated Total Reflectance-Fourier Transform Infrared Spectroscopy (ATR/FTIR), respectively. Optical microscopy (OM) and field emission scanning electron microscopy (FE-SEM) were used to investigate structure of the coatings. The results show an increase of the hydrolysis water content at a constant organic/inorganic molar ratio and other variable parameters increases adhesion of coatings to substrate, and optimum coatings exhibit excellent mechanical properties as well as adhesive to the substrate.     

Styrene butadiene co-polymer based conducting polymer composite as an effective corrosion protective coating

Electroactive conducting polymer composite coatings of polyaniline (PANI) are electrosynthesized on styrene–butadiene rubber (SBR) coated stainless steel electrode by potentiostatic method using aqueous H₂SO₄ as supporting electrolyte. The protective behaviour of these coatings in different corrosion media (3.5% NaCl and 0.5 M HCl) is investigated using Tafel polarization curves, open circuit potential measurements and electrochemical impedance spectroscopy. The results reveal that SBR/PANI composite coating is much better in corrosion protection than simple PANI coating. The corrosion potential of composite films shifts to more noble values indicating that SBR/PANI composite coating act as an effective corrosion protective layer.     

Influence of annealing temperature on the structural and anti-corrosion characteristics of sol–gel derived,spin-coated thin films

Recently, an aqueous particulate sol–gel process using metallic chloride precursors was introduced to synthesize zirconium titanate. In this paper, the effect of annealing temperature on the structural and corrosion protection characteristics of spin-coated thin films obtained from this sol–gel system was investigated. Based on scanning electron microscopy, transmission electron microscopy, atomic force microscopy, and spectroscopic reflectometry studies, it was found that the flatness and thickness of the thin films were decreased by increasing the annealing temperature. Also, the corrosion protection of stainless steel AISI 316L provided by the prepared coatings, as analyzed by electrochemical potentiodynamic polarization experiments in a simulated body fluid, was improved in this order: 500 °C-annealed sample<900 °C-annealed sample<700 °C-annealed sample, attributed to a compromise between the defect density and the adhesion of the films to the substrate.     

Surface properties and moisture behaviour of pine and heat-treated spruce modified with alkoxysilanes by sol–gel process

The surface morphology and moisture behaviour of pine (Pinus sylvestris) sapwood and heat-treated spruce (Picea abies) deposited with two types of silane-based sol–gel coatings were studied by atomic force microscopy (AFM) and water contact angle measurement. The chemical composition and distribution of sol–gel coatings on wood surfaces were investigated by X-ray photoelectron spectroscopy (XPS) and time-of-flight secondary ion mass spectrometry (ToF-SIMS). The AFM images revealed that the sol–gel coatings applied by spreading covered the fine structure of the wood substrates. The surface roughness analysis of the AFM topographical images indicated that the sol–gel coatings, especially the one with short aliphatic chain, had a tendency to smooth the wood surface. The XPS results confirmed that the sol–gel coatings had successfully deposited onto pine sapwood and heat-treated spruce changing their surface chemistries. ToF-SIMS images showing Si ion distribution on treated surfaces revealed that the coatings fully covered pine sapwood surfaces. The thin coating layers formed on heat-treated spruce surfaces followed the original wood surface structure. The contact angle measurements indicated that the water repellent properties of both pine and heat-treated spruce were improved to certain extent by the sol–gel coatings.     

Corrosion behaviour of sol–gel treated and painted AA2024 aluminium alloy

Design, development and scale-up of environmentally friendly coatings are very important in order to replace chromate based coatings for aluminium alloys. Barrier properties, paint adhesion and possibly self-healing ability are relevant aspects for replacement of chromate-based pre-treatments. Sol–gel materials are candidates for use in protective coating applications, as it is possible to form highly adherent and chemically inert oxide films on metal substrates.     

Preparation and characterization of sol–gel derived UV-curable organo-silica–titania hybrid coatings

In this work, UV-curable organic–inorganic hybrid coatings based on cycloaliphatic epoxyacrylate were prepared by sol–gel technique. Acid catalyzed solutions of tetraethylorthosilane (TEOS) containing Ti:acac complex were used as an inorganic precursors. UV-curable, transparent hybrid coating materials were applied on plexiglass substrates and their coating performance was investigated by the analyses of various tests such as hardness, gloss, cross-cut adhesion tests, stress–strain test and optical transmission. The mechanical measurements showed that, the tensile properties of coatings underwent an abrupt change from a brittle to a tough material when the inorganic part was incorporated into the cycloaliphatic epoxy acrylate based organic network. UV–vis transmission spectroscopy results indicated that the hybrid materials with high titanium content have good transparences. The thermal behaviour of the coatings was also evaluated. It is observed that the thermal stability of the hybrids is enhanced with incorporation of sol–gel precursor.     

Preparation of hybrid silica sol–gel coatings on mild steel surfaces and evaluation of their corrosion resistance

Hybrid silica sol–gel coatings were prepared on mild steel substrate by dip coating technique. The coatings were subsequently heat treated at 200 °C in order to improve their corrosion properties. The coating sols were synthesized using Glycidoxypropyltrimethoxysilane (glymo) and Aminopropylethoxysilane (ameo) as precursor materials. Potentiodynamic polarization curves were derived and Electrochemical Impedance Spectroscopy (EIS) measurements were made in NaCl solution. The surface and cross-section morphology of coated specimens were characterized by scanning electron microscopy (SEM). Fourier transformed infrared (FTIR) analysis was used to identify the presence of various functional groups in the coating solutions. A comparison of the corrosion resistance of the coated and uncoated mild steel was presented. The results indicated that the corrosion resistance of the coated mild steel was improved considerably.     

Self-healing corrosion protection by nanostructure sol–gel impregnated with propargyl alcohol

Zirconia based nanostructured hybrid sol–gel coating, impregnated with propargyl alcohol (PA) to hinder corrosion of mild steel was studied. Zirconia nano-particles (TPOZ) contained sol–gel was synthesized using 3-glycidoxypropyltrimethoxysilane (GPTMS) as precursor and subsequently optimized for internal cohesion as well as adhesion to the mild steel substrate to assess the consequent effect on suppression of corrosion damage in 0.5 M NaCl solution. Electrochemical Impedance Spectroscopy (EIS) and Scanning Electron Microscopy (SEM) results demonstrated the effect of coating integrity on impeding corrosion. Experiments on mild steel specimens coated with hybrid sol–gel films following mechanical polishing render superior corrosion resistance to mild steel in contrast to those undergoing electrochemical polishing with marked lower surface roughness. Results also proved of beneficial effect of low and exact concentration of PA on sol–gel coat's barrier properties evident from diminished corrosion current and other electrochemical indicators.     

Photocatalytic activity of thin TiO2 films deposited using sol–gel and plasma enhanced chemical vapor deposition methods

Thin titanium dioxide films, deposited using RF PECVD and sol–gel techniques, were studied comparatively with respect to their bactericidal as well as self-cleaning properties. The effect of the deposition process on film morphology, chemical and crystalline structure, bactericidal activity and hydrophilic properties was investigated using scanning electron microscopy (SEM), atomic force microscopy (AFM), X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), surface profilometry, optical microscopy and contact angle measurements. It was found that the bactericidal activity of amorphous TiO₂ films, produced using the RF PECVD method, as either comparable to or better than those of crystalline (anatase) films deposited by means of the sol–gel technique. One reason for such advantageous behavior of plasma deposited materials is thought to be their substantially higher surface roughness, as revealed by AFM measurements. The hydrophilic effect, induced with UV irradiation, was strongest in the case of sol–gel films, but the RF PECVD synthesized coatings were found to be only slightly less hydrophilic. The conclusion follows that both sol–gel and RF PECVD techniques are equally capable of producing titanium dioxide films of high photocatalytic quality.     

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.