Sol-gel ZrO2 coatings for chemical protection of stainless steel

ZrO₂ coatings deposited on 316 L stainless steel sheets were synthesized by sol-gel method using Zr(OC₃H₇)₄ as precursor and isopropanol, glacial acetic acid, and water as solvents for application with ultrasounds. Different solutions for dip-coating were prepared with compositions varying between 0.025 and 0.9 mol/dm³ of ZrO₂. X-ray diffraction shows that the films densified at 800°C are crystalline with a tetragonal structure. The thickness of the coatings varied from 0.35–0.75 m. The influence of the ZrO₂ coatings on the corrosion behavior of stainless steel substrates in aqueous NaCl was studied through potentiodynamic polarization curves at 1 mV/s. The values of the electrochemical parameters allow for an explanation of the role of the films in the increased resistance of steel against corrosion in moderately aggressive environments.     

XPS depth profile study of porous zirconia films deposited on stainless steel by spray pyrolysis: the problem of substrate corrosion

Zirconia (ZrO₂) films of tissue‐like structure and narrow pore size distribution have been deposited by spray pyrolysis using aqueous zirconyl chloride octahydrate (ZrOCl₂·8H₂O) precursor solutions. Stainless‐steel sheets, protected or unprotected by a ZnO barrier layer, have been used as the substrate material held at 473 K. The ZnO barrier layers have been deposited on the stainless steel held at 523 K by spray pyrolysis using a zinc acetate precursor. Their property of corrosion protection to stainless steel has been proved by electrochemical polarization measurements in 0.5 M NaCl solution. A complementary study of XPS (depth profiling, mapping) and x‐ray diffraction has shown that the unprotected steel substrates were corroded during ZrO₂ film post‐annealing in air at T ≥ 773 K, whereas steel substrates protected with a compact barrier layer of crystalline ZnO before ZrO₂ film deposition did not show surface corrosion even after annealing up to 997 K. Copyright © 2004 John Wiley & Sons, Ltd.     

Ormocer (ZrO2-PMMA) Films for Stainless Steel Corrosion Protection

The chemical protection of 316 L stainless steel coated with ORMOCER coatings of polymethylmethacrylate (PMMA) and ZrO₂ has been verified. The coatings were dip-coated on the substrates from sols prepared by mixing zirconium propoxide (ZrOC₃H₇)₄, isopropanol (C₃H₇OH), glacial acetic acid (CH₃COOH), polymethylmethacrylate and water under application of ultrasounds. The films were heat treated between 40 and 300°C in air up to 20 h. Their morphology was studied by electron scanning microscopy (SEM). Their anticorrosion behavior was analysed in 0.5M-H₂SO₄ solutions through potentiodynamic polarization curves at room temperature.The influence of the sol preparation, coating composition as well as of the duration and temperature of heat treatments on the corrosion parameters is reported. The films act as geometric blocking layers against the corrosive media and increase the lifetime of the substrate up to a factor 30.     

Sol-gel coatings for chemical protection of stainless steel

Sol-gel thin coatings of ZrO₂, SiO₂, 70SiO₂-30TiO₂ and 88SiO₂-12Al₂O₃ compositions (mole %) have been prepared from sonocatalyzed sols and deposited by dip-coating technique on 316L stainless steel foils. The influence of the coatings on the chemical corrosion of the substrate has been measured through potentiodynamic polarization curves in aqueous 15% H₂SO₄ solution between 25 and 50°C. The values of the corrosion potential, polarization resistance and corrosion rate have been determined. Analysis of the data combined with scanning electron microscopy studies indicate that the films act as a geometric blocking against exposure to the corrosive media and increase the lifetime of the substrate up to a factor 8.5.     

Electrochemical behaviour of SiO2 sol-gel coatings on stainless steel

SiO₂ coatings onto stainless steel substrates have been prepared by sol-gel in order to study the performance and mechanism of attack in different corrosive solutions. The electrochemical behaviour of the samples has been evaluated by Electrochemical Impedance Spectroscopy using NaCl and HCl as electrolytes. Comparative tests have been performed on samples with one and two silica layers as well as on uncoated ones. SiO₂ coatings produce no important protection of stainless steels subjected to electrochemical corrosion. This behaviour may be explained by micropores and microcracks produced during the coating sintering.     

Sol-Gel Processing of Zirconia Coating for HR Mirrors with High Laser Damage Threshold

High laser-damage resistant coatings are very important in high power laser systems. In this study ZrO₂ thin films are prepared by sol-gel spin-coating technology from suitable zirconia aqueous colloidal suspensions containing nano-crystalline ZrO₂ at room temperature synthesized by a hydrothermal process from an inorganic precursor (ZrOCl₂·8H₂O). By adding a soluble organic binder PVP to the suspension prior to application, it is possible to substantially increase the coating refractive index and the abrasion-resistance as well as the laser damage threshold. The features of the coatings and the colloidal suspensions are investigated. Multilayer highly reflective dielectric coatings are also elaborated by applying quarterwave-thick alternating coatings of the binder-aided zirconia and silica, which is prepared with the sol-gel process from TEOS. To achieve 99% reflectivity, 19–21 layers are required. Single shot laser damage tests are carried out using a high power laser at 1064 nm wavelength with a pulse duration of 2.5 ns. The laser damage thresholds of 18 and 15 J/cm² are achieved for single ZrO₂-PVP coating and ZrO₂-PVP/SiO₂ multilayers respectively.     

Synthesis and Properties of Cerium and Titanium Oxide Thin Coatings for Corrosion Protection of 304 Stainless Steel

Powders and thin coatings of ceria and titania were synthesized from aqueous and solvent-based precursors. Thin coatings were deposited on polished 304 stainless steel coupons by dipping them in the appropriate sol-gel oxide precursors. The coatings were subsequently densified and crystallized at several hundreds of degrees. It was possible to obtain dense titania coatings by applying thin coatings of cerium dioxide prior to titania on stainless steel substrates. Underlayer ceria coatings proved to be pivotal in obtaining dense titania coatings and preserving the integrity of the stainless steel while going through the high temperature treatments. The effect of processing parameters such as the atmosphere of heat-treatment, and temperature on the microstructure and crystal structure of the films and powders of ceria and titania was investigated. X-ray diffraction was used to identify the crystal structure of films and powders upon heat-treatment. Electrochemical measurements in NaCl, and analytical techniques such as SEM and EDX were used to evaluate the corrosion performance and pitting morphology of coated samples. A composite coating of ceria and titania was able to prevent crevice corrosion and increase the pitting resistance of the 304 stainless steel relative to the uncoated substrate.     

Bioactive and Protective Sol-Gel Coatings on Metals for Orthopaedic Prostheses

The aim of this work has been the preparation and evaluation of sol-gel coatings for clinical applications. Research was focussed in the development of highly corrosion resistant and/or bioactive sol-gel coatings onto AISI 316L stainless steel. Hybrid SiO₂ sol-gel coatings inhibited corrosion and Fe diffusion, although no signal of bioactivity was detected. The inclusion of Ca- and P-alcoxides in the sol composition did not promote bioactivity. Bioactive coatings were obtained from suspensions prepared by adding glass (CaO·SiO₂·P₂O₅) particles to an hybrid organic-inorganic SiO₂ sol. The dissolution of glass particles promoted in vitro induction of apatite along with a slight reduction in the corrosion resistance of coated pieces. By combining an inner SiO₂ hybrid film acting as barrier against corrosion with an outer coating containing bioactive glass particles, a significant improvement in the electrochemical behaviour was observed. This double-layered coating showed in vitro signals of bioactivity, and preliminary in vivo tests gave promising results.     

Photo-Induced Hydrophilicity of TiO<Subscript>2</Subscript> Films Deposited on Stainless Steel via Sol-Gel Technique

The photo-induced hydrophilicity of TiO₂ films deposited on stainless steel substrates and silicon wafers using two different sol-gel routes has been investigated. The results indicate that crystalline titanium oxide films with excellent hydrophilic properties can be obtained on silicon wafer with both routes. XPS and XRD data reveal that films deposited on stainless steel exhibit crystallization features similar to those of films deposited on silicon wafers, and only differ by their oxidation degree owing to a TiO₂ reduction process associated to a diffusion of iron ions during deposition of the acidic sol and/or high temperature post-treatment. Consequently, hydrophilic properties of films deposited on stainless steel are inhibited. The deposition of a SiO_x barrier layer at the film/substrate interface allows preventing such a detrimental substrate influence. A low temperature deposition route of the TiO₂ film associated to the presence of a barrier layer yields best results in preventing iron contamination of the films.     

Preparation of YSZ Coated AISI-Type 316L Stainless Steel by the Sol-Gel Coating Method and Its Corrosion Behavior in Molten Carbonate

The effect of heat-treatment conditions on the corrosion behavior of yttria stabilized zirconia (YSZ) coated AISI-type 316L stainless steels in molten carbonate are investigated. YSZ films on stainless steel were prepared by the sol-gel method. While the sample heat-treated at 800°C for 2 hours in air has an uneven surface microstructure with macrocracks, a YSZ coated sample heat-treated in argon has an even microstructure. The polarization resistance and corrosion rate of YSZ coated sample heat-treated in air were deteriorated from 6.948 cm² and 364.7 mpy (millimeter per year) to 3.291 cm² and 769.8 mpy, respectively, by the corrosion for 100 hours due to its poor surface microstructures. At the same experimental condition, meanwhile, those corrosion parameters of YSZ coated sample heat-treated in argon were 15.43 cm² and 164.2 mpy, respectively, and those were improved to 18.83 cm² and 134.6 mpy after the corrosion for 100 hours. This is attributed to the YSZ film with well developed surface microstructures. The concentration profiles of elements and X-ray diffractograms indicate that the oxide layer of YSZ coated sample heat-treated in argon had a triple layer structure composed of outer YSZ film, in between Fe₂O₃ layer, and inner chromium rich layer during corrosion.     

Water‐based ZrO2 pretreatment for AA2024 aluminum alloy

Design, development and scale‐up of environmentally friendly coatings are very important in order to replace chromate‐based coatings for aluminum alloys. 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. ZrO₂ pretreatments were developed by means of sol–gel technology. An inorganic salt was employed as Zr precursor in an aqueous solution. The deposition was initially carried out on AA2024 by means of dip and spray technology at laboratory scale. Corrosion inhibitors were introduced to improve corrosion behavior of the films. At a later stage, coating deposition was carried out with a robot‐controlled air‐pressure gun in spraying cabins in order to evaluate industrial production of the pretreatments. Film morphology and composition were investigated by means of SEM‐EDXS and GDOES. The electrochemical behavior of the ZrO₂ pretreatments was investigated by means of potentiodynamic polarization. The water‐based ZrO₂ pretreatment investigated in this work is thin and well adherent on the substrate. Barrier properties are similar to those of chromate conversion coating. Results on samples produced with robot‐controlled air‐pressure gun indicate that ZrO₂ pretreatments are suitable for industrial application. Copyright © 2009 John Wiley & Sons, Ltd.     

Structural and electrochemical characterization of sputter-deposited nitrided NiCr alloys

Nickel-based coatings are potential candidates for the protection of electrochemical dissolution of steel surfaces. Such coatings, elaborated by magnetron sputtering in a nitrogen atmosphere, offer good corrosion protection, good adherence as well as stability for metallic structures. NiCr alloys with almost constant composition have been deposited with different nitrogen contents on stainless steel and carbon steel surfaces. The coating uniformity, homogeneity, composition and crystallinity have been studied by scanning electron microscopy, energy-dispersive X-ray spectrometry, atomic force microscopy and X-ray diffraction techniques. The corrosion degradation behavior of all the samples was tested in NaCl and NaCl and CO₂ mixture exposures using electrochemical impedance spectroscopy measurements. Nitrided NiCr alloys on a stainless steel substrate resulted with better adhesion than carbon steel, by delaying the corrosion mechanism when exposed to NaCl and CO₂ solution. A comparison of the corrosion resistive behavior of the substrates (stainless steel, carbon steel) and the coatings is made by using the electrical capacitance concept from a double-layer model for the coating–metal interface.     

Investigation of Glass-Like Sol-Gel Coatings for Corrosion Protection of Stainless Steel Against Liquid and Gaseous Attack

Glass-like sol-gel coatings have been investigated as corrosion protective coatings on stainless steel. Magnesium- and borosilicate coatings with thickness of about 100–700 nm and methyl-modified SiO2 coatings with a thickness of about 2 m were deposited on stainless steel plates by dip-coating. The coatings were densified between 400°C and 500°C in different atmospheres (N2, air) for 1 h. The corrosion protection against gaseous attack was investigated by accelerated corrosion tests, at 800°C in air for 1 h. A corrosion protection factor was calculated from the relation Fe/Fe2O3, determined by XRD on the surface of coated and uncoated samples. Methyl-modified SiO2 coatings showed a protection factor, which was 2 orders of magnitude higher than for the other coatings. Electrochemical investigations were performed on samples submerged in a NaCl solution for 200 h. The corrosion propagation, polarization resistance and impedance vector were measured. For accelerated corrosion tests, polarization intensity curves were determined for high potentials of up to 1 V. Again excellent results were obtained for the methyl-modified SiO2 coatings, which remained passive for 200 h. Results of the salt spray corrosion test, however, showed no corrosion protection by the sol-gel coatings. After 2000 h in the salt spray chamber the steel was corroded and the coatings peeled off. It is concluded that for the further development of these coatings an improved interfacial passivation will be required.     

Low Temperature Preparation of High Refractive Index and Mechanically Resistant Sol-gel TiO2 Films for Multilayer Antireflective Coating Applications

TiO₂ sol-gel thin films have attracted a large attention for applications which require high refractive index transparent layers. In this work, sol-gel TiO₂ layers were prepared by Aerosol-gel deposition followed by a thermal treatment procedure in air. Depending on the experimental conditions, abrasion resistant and high refractive index layers could be obtained after post-treatment at only 110°C. In this paper, the experimental parameters which allow the preparation of functional TiO₂ sol-gel layers at such low temperature are discussed. It is concluded that the preparation of high refractive index and mechanically resistant TiO₂ layers can be interpreted in terms of competition between polycondensation and densification mechanisms. This result allows to envisage the sol-gel processing at low temperature of multilayer antireflective coatings.     

Silica-Zirconia Sol–Gel Coatings Obtained by Different Synthesis Routes

Homogeneous xSiO₂-(1−x)ZrO₂ coatings have been prepared onto glass-slides, monocrystalline Si and stainless steel (AISI 304) using sols prepared via acid and basic catalysis. Zirconium tetrabutoxide (TBOZr), zirconium n-propoxide (TPZ), tetraethoxysilane (TEOS) and methyltriethoxysilane (MTES) were used as precursors of zirconia and silica, respectively. The different parameters involved in the synthesis procedure, as molar ratios H₂O/alkoxides, NaOH/alkoxides, and sintering temperature have been analysed, correlating the stability and rheological properties of the sols. The evolution and structure of the sols and coatings have been studied by FTIR. Coatings have been prepared by dipping from acid and basic sols. Electrophoretic Deposition (EPD) technique has also been used to prepare coatings onto stainless steel from basic particulate sols in order to increase the critical thickness. A maximum thickness of 0.5 μ m was reached by both dipping and EPD process for 75SiO₂: 25 ZrO₂ composition. The critical thickness decreases with ZrO₂ amount depending strongly of the drying conditions. Si–O–Zr bonds have been identified by FTIR, indicating the existence of mixed network Si–O–Zr in the coatings obtained by the different routes. Crystallisation of ZrO₂(t) was only observed at high sintering temperature (900^∘C) by FTIR and confirmed by DRX.     

Protective coatings based on Mn-Co spinel for current collectors of solid oxide fuel cells

The method of electrostatic spray pyrolysis was designed to apply protective coatings based on Mn-Co spinel to ferrite stainless steels (Crofer22APU and 08Kh18T1). The comparative thermogravimetric (TG) studies of ferrite stainless steels with and without protective coatings were carried out. The electrochemical characteristics of protective coatings exposed to long current loading were studied. The formation processes of Cr₂O₃ oxide films were studied at the contact of ferrite stainless steel with La_0.8Sr_0.2MnO₃ ionic and electronic conductor. The coatings of Mn-Co spinel were shown not preventing formation of continuous oxide film on the stainless steel surface.     

Two-Dimensional Sol-Gel Synthesis of Ultrathin Zirconia and Hetero-Layered Titania/Zirconia Films

Synthesis of ZrO₂ and hetero-layered TiO₂/ZrO₂ ultrathin films was investigated by two-dimensional sol-gel process assisted by n-octadecylacetoacetate (C₁₈AA). When a hexane solution of tetrabutoxyzirconium (TBZ) and C₁₈AA was spread on the water surface, Zr-based gel films stabilized with C₁₈AA were formed at the air/water interface. After deposition on substrates, the gel films were successfully transformed into ZrO₂ ultrathin films by heating at 773 K for 0.5 h, the thickness of which was controllable on the order of sub-nanometer level by the number of gel-layer deposition and the molar ratio of [TBZ]/[C₁₈AA]. Well-organized hetero-multilayers composed of ultrathin TiO₂ and ZrO₂ layers could be fabricated by the alternate deposition of C₁₈AA-stabilized Ti- and Zr-gel films.     

Sol-Gel Coatings on 316L Steel for Clinical Applications

SiO2 and SiO2-CaO-P2O5 coatings have been prepared by dipping electropolished stainless steel 316L samples and microscope glass slides in three different sol-gel solutions. Multilayered dense SiO2 coatings, and thick silica films obtained from equimolar contents of TEOS and MTES were used. The latter were able to strongly reduce both the corrosion attack on the steel and the iron diffusion to the sample surface. SiO2-CaO-P2O5 coatings were also obtained and applied onto the silica films, in order to provide a bioactive external surface for contact with living tissue. In-vitro evaluation of these coatings and films is discussed.     

Effect of thermal annealing of poly(3-octylthiophene) films covered stainless steel on corrosion properties

The effect of thermal annealing of poly(3-octylthiophene) (P3OT) coatings on the corrosion inhibition of stainless steel in an NaCl solution was investigated. P3OT was synthesized by direct oxidation of the 3-octylthiophene monomer with ferric chloride (FeCl₃) as oxidant. P3OT films were deposited by drop-casting technique onto 304 stainless steel electrode (304SS). 304SS coated with P3OT films were thermally annealed during 30 h at different temperatures (55°C, 80°C, and 100°C). The corrosion resistance of stainless steel coated with P3OT in 0.5 M NaCl aqueous solution at room temperature was investigated by using potentiodynamic polarization curves, linear polarization resistance, and electrochemical impedance spectroscopy. The results indicated that the thermal treatment at 80°C and 100°C of P3OT films improved the corrosion resistance of the stainless steel in NaCl solution; the speed of corrosion diminished in an order of magnitude with regard to the 304SS. In order to study the temperature effect in the morphology of the coatings before and after the corrosive environment and correlate it with corrosion protection, atomic force microscopy and scanning electron microscopy were used. Morphological study showed that when the films are heated, the grain size increased and a denser surface was obtained, which benefited the barrier properties of the film.     

Stress and Moisture-Sorption in Ozone-Annealed Films of Zirconium Oxide Obtained from Sol-Gel

The stress development in zirconium oxide films prepared by sol-gel and annealed under ozone-enriched oxygen has been investigated. The organic compounds are mostly oxidized at 200°C with ozone and the stress rises up to higher values than the stress in films annealed with pure oxygen between 200 to 400°C. During exposure to humid air of films annealed at 150°C under pure or ozone-enriched oxygen chemical transformations of organic compounds have been observed. The moisture-induced stress change during film exposure to the ambient air also has been investigated. The competition between hydration of ZrO₂, H-bound formation, surface ionization and capillary condensation mechanisms is discussed.