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.     

Sol-Gel Deposition of ZrO2 Films in Air and in Oxygen-Free Atmospheres for Chemical Protection of 304 Stainless Steel: A Comparative Corrosion Study

ZrO₂ coatings for corrosion protection were deposited on 304 stainless steel by sol-gel method using zirconium propoxide as precursor and densified in air and in oxygen-free (argon or nitrogen) atmospheres. XRD and IR data of the films were practically independent of the atmosphere used in the densification step showing that the ceramic oxide is properly formed from the precursor. The corrosion behavior of the stainless steel substrate was studied by potentiodynamic polarization curves in the absence and the presence of ZrO₂ coatings prepared in air, argon or nitrogen. The coatings extended the lifetime of the material by a factor of almost eight in a very aggressive environment, independently of the preparation procedure. The possibility of depositing pure or mixed oxide films by sol-gel methods in the absence of additional oxygen will allow the preparation of specific coatings onto oxygen-reactive substrates.     

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.     

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.     

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.     

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.     

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.     

Cerium hybrid silica coatings on stainless steel AISI 304 substrate

AISI 304 Stainless Steel is widely used in different industrial fields because of its mechanical and corrosion properties. However, its tendency to corrosion in presence of halide ions limits the applications. One strategy to improve the corrosion resistance is the use of coatings barriers containing corrosion inhibitors in their formulation. The lanthanides present attractive green and corrosion properties for the substitution of chromates, which are the most common substances used as corrosion protection. However, these compounds are highly toxic, and an intense effort is being undertaken to replace them. Cerium is a good alternative because of its relatively low cost and abundance. It fulfils the basics requirements for being considered an alternative inhibitor: the ions form insoluble hydroxides and they present low toxicity. Inorganic and hybrid sol-gel coatings have been developed to increase the corrosion resistance of metals and they provide an excellent vehicle for the incorporation of secondary phases including particles and metal ions as cerium ions. The aim of this work was to study the influence of the incorporation of cerium ions in hybrid silica sol-gel coatings deposited on AISI 304 stainless steel as substrate as a potential replacement of chromate treatments. This system should combine the barrier protection effect of silica coating with the corrosion inhibitor effect of the cerium ions inside the coatings. After 7 days of immersion in NaCl, coated substrates showed lower current densities than the bare steel, although the coatings produced from Ce (III) salts experience a slight weakening in time and those obtained from Ce (IV) chemicals evidence an enhance in the coating performance, probably due to the plugging of corrosion products in the defective areas of the film.     

Electrophoretic Deposition of Hydroxyapatite Coatings on Metal Substrates: A Nanoparticulate Dual-Coating Approach

Hydroxyapatite coatings can be readily deposited on metal substrates by electrophoretic deposition. However, subsequent sintering is highly problematic owing to the fact that temperatures in excess of 1100°C are required for commercial hydroxyapatite powders to achieve high density. Such temperatures damage the metal and induce metal-catalysed decomposition of the hydroxyapatite. Furthermore, the firing shrinkage of the hydroxyapatite coating on a constraining metal substrate leads to severe cracking. The present study has overcome these problems using a novel approach: the use of aged nanoparticulate hydroxyapatite sols (lower sintering temperature) and a dual coating strategy that overcomes the cracking problem. Dual layers of uncalcined hydroxyapatite (HAp) powder were electrophoretically coated on Ti, Ti6Al4V and 316L stainless steel metal substrates, sintered at 875–1000°C, and characterised by SEM and XRD, and interfacial shear strength measurement. Dual coatings on stainless steel had an average high bond strength (about 23 MPa), and dual coatings on titanium and titanium alloy had moderate strengths (about 14 and 11 MPa, respectively), in comparison with the measured shear strength of bone (35 MPa). SEM and XRD demonstrated that the second layer blended seamlessly with the first and filled the cracks in the first. The superior result on stainless steel is attributed to a more appropriate thermal expansion match with hydroxyapatite, the thinner oxide layer, or a combination of these factors.     

Effect of Sintering Temperature on the Corrosion and Wear Behavior of Protective SiO2-Based Sol-Gel Coatings

Sol-gel hybrid organic-inorganic and inorganic SiO₂-based protective coatings with and without added 3 m glass particles were developed and tested for their corrosion and wear behavior of an stainless steel substrate (AISI316L). The corrosion resistance greatly increases by incorporating glass particles in the sols. The incorporation of particles in the coatings allows the synthesis of thicker crack-free coatings. On the other hand, the corrosion resistance increases for coatings with a higher organic content obtained at lower sintering temperature. These coatings are also highly stable in saline aqueous solutions. However, the wear resistance is badly affected by the hybrid character of the SiO₂ matrix. The optimum coating process in terms of corrosion and wear resistance, appears to be a hybrid system with a dense SiO₂ network achieved at intermediate sintering temperatures.     

Characterization and corrosion resistance of organically modified silicate/MO2 (M = Zr,Ti, or Ce) hybrid coatings on a 6061‐T6 aluminum alloy

Hybrid coatings based on organically modified silicate (Ormosil)/ZrO₂ (0–1.0 wt %) and Ormosil/MO₂ (M = Ti or Ce) were synthesized through a sol–gel technique. Tetraethylenepentamine, 3‐glycidoxypropyltrimethoxysilane, tetraethoxysilane, and MO₂ (M = Zr, Ti, or Ce) metallic particle 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 ZrO₂ content and the metallic particle type on the chain dynamics, thermal stability, and corrosion performance 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 crosslinked and dense and adhered to the aluminum alloy substrates. The thermal stability and the apparent activation energy, evaluated by van Krevelen's method, of the hybrid coatings depended on the ZrO₂ content and on the metallic particle type. Potentiodynamic and salt‐spray analysis revealed that the hybrid films provided exceptional barrier and corrosion protection in comparison with untreated aluminum alloy substrates. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 335–342, 2006     

A study on the electrochemical polymerization, characterization, and corrosion protection of o-toluidine on steel

Poly(o-toluidine) (POT) coatings were electrochemically synthesized on 304 stainless steel using cyclic voltammetric method. These coatings were characterized by Fourier transform infrared spectroscopy, UV–vis absorption spectroscopy, and cyclic voltammetry. The corrosion performance of POT coating in aqueous 3 wt% sodium chloride was assessed by the electrochemical techniques such as open circuit potential measurements, potentiodynamic polarization technique, cyclic potentiodynamic polarization measurements, and electrochemical impedance spectroscopy. The results reveal that POT coating on 304 stainless steel prevents general and localized corrosion, and reduces the exchange current density almost by a factor of 45 than bare 304 stainless steel.     

Poly(3-octylthiophene) and polystyrene blends thermally treated as coatings for corrosion protection of stainless steel 304

The effect of thermal annealing of poly(3-octylthiophene) (P3OT) and polystyrene (PS) blend coatings on the corrosion inhibition of stainless steel in a 0.5 M NaCl solution was investigated. P3OT was synthesized by direct oxidation of the 3-octylthiophene monomer with ferric chloride (FeCl₃) as oxidant. Stainless steel electrodes with mirror finish were coated with P3OT/PS blend by drop-casting technique. In order to study the temperature effect on the function like physical barrier against the corrosive species of P3OT/PS polymeric blend, the coatings were thermally annealed at three different temperatures (55?°C, 80?°C, and 100?°C). The corrosion behavior of P3OT/PS-coated stainless steel was investigated in 0.5 M NaCl at room temperature, by using potentiodynamic polarization curves, linear polarization resistance (LPR), and electrochemical impedance spectroscopy. The LPR values indicated that, at 100?°C, P3OT/PS coatings showed a better protection of the 304 stainless steel in 0.5 M NaCl; the corrosion rate diminished in two orders of magnitude with regard to the bare stainless steel. The superficial morphology of the coatings before and after the corrosive environment was researched by atomic force microscopy, optic microscopy, and scanning electronic microscopy. Morphological study showed that the increased temperature benefited the integration of the two polymeric phases, which improved the barrier properties of the coatings. The coating/metal adhesion and the coating thickness were evaluated. The temperature increases the adhesion degree coating/substrate; thus, the coating annealed at 100?°C showed the best adhesion.     

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.     

Corrosion processes below organic coatings

The protective mechanisms of paint systems of a 1-pack polyurethane- and an epoxy/2-pack polyurethane-coating system with zinc dust priming coats were investigated on blast-cleaned and on hand-cleaned steel substrates. The coated panels were exposed to the salt spray test and to a cyclic alternating test (VDA 621-415). The protective effect was assessed in determining adhesion, undermining at scratches, water uptake and the corrosion potential. On blast cleaned steel substrates the adhesion of the investigated coating systems was not influenced by water uptake of the coatings. Scratches are especially cathodically protected. On hand-cleaned steel surfaces the rust layer between steel substrate and coating can participate in the corrosion process with rust reduction as cathodic partial reaction. The change of rust morphology is the reason for the loss of adhesion of coating. At scratches rust reduction takes also place at the edge of the defect which is independent from pigments of the base coating.     

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.     

SiO2纳米粒子对溶胶凝胶涂层性能的影响

在高强钢表面制备了防护性溶胶凝胶涂层,并研究了不同浓度二氧化硅纳米粒子的加入对于涂层形貌、耐蚀性和硬度的影响。采用扫描电子显微镜(SEM)和电子能谱(EDS)观察了涂层的微观结构和成分;采用显微硬度计测试了涂层的硬度;采用电化学方法研究了二氧化硅纳米粒子的浓度对于涂层耐蚀性能的影响;采用傅里叶红外光谱研究涂层的化学结构,进而探讨了二氧化硅纳米粒子对于涂层的强化机理。结果显示涂层加入二氧化硅纳米粒子的最佳浓度为500 mg.L-1,此条件下的涂层表面均匀致密,有较高的硬度并且在3.5%NaCl溶液中体现出较好的耐蚀作用。纳米粒子在溶胶中反应形成活性羟基基团并与硅烷发生反应生成空间网状结构,从而强化涂层。     

Anticorrosive and Microbial Inhibition Performance of a Coating Loaded with Andrographis paniculata on Stainless Steel in Seawater

With the trend for green technology, the study focused on utilizing a forgotten herb to produce an eco-friendly coating. Andrographis paniculata or the kalmegh leaves extract (KLE) has been investigated for its abilities in retarding the corrosion process due to its excellent anti-oxidative and antimicrobial properties. Here, KLE was employed as a novel additive in coatings and formulations were made by varying its wt%: 0, 3, 6, 9, and 12. These were applied to stainless steel 316L immersed in seawater for up to 50 days. The samples were characterized and analyzed to measure effectiveness of inhibition of corrosion and microbial growth. The best concentration was revealed to be 6 wt% KLE; it exhibited the highest performance in improving the ionic resistance of the coating and reducing the growth of bacteria.     

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.     

Improved self-healing performance of polymeric nanocomposites reinforced with talc nanoparticles (TNPs) and urea-formaldehyde microcapsules (UFMCs)

The present work reports the self-healing performance of the epoxy based polymeric nanocomposite coatings containing different concentrations (1 and 3 wt%) of talc nanoparticles (TNPs) modified with sodium nitrate (NaNO₃), and a fixed amount (5 wt%) of urea-formaldehyde microcapsules (UFMCs) encapsulated with linseed oil (LO). The polymeric nanocomposites were developed, coated on polished steel substrates, and their structural, thermal, and self-healing characteristics were investigated using various techniques. The successful loading (~wt 10%) of NaNO₃ into TNPs, which can be ascribed to the involvement of physio-chemical adsorption mechanism, is validated and proceeds without altering the TNPs parent lamellae structure. The performed tests elucidated that the self-release of the corrosion inhibitor (NaNO₃) from TNPs is sensitive to the pH of the solution and immersion time. In addition, the release of the linseed oil (self-healing agent) from UFMCs in response to the external damage was found to be a time-dependent process. The superior self-healing and corrosion inhibition performance of the protective polymeric nanocomposites coatings containing 3 wt% TNPs and UFMCs/LO are proven using the electrochemical impedance spectroscopy (EIS) studies. A careful selection of smart carriers, inhibitor, and self-healing agent compatible with polymeric matrix has enabled to attain decent self-healing and convincing corrosion inhibition efficiency of 99.9% and 99.5%, respectively, for polymeric nanocomposites coatings containing 3 and 1 wt% TNPs, making them attractive for many industrial applications.