Development of analytical procedures for the determination of hexavalent chromium in corrosion prevention coatings used in the automotive industry

The European directive 2000/53/EC limits the use of Cr(VI) in vehicle manufacturing. Although a maximum of 2 g of Cr(VI) was authorised per vehicle for corrosion prevention coatings of key components, since July 2007 its use has been prohibited except for some particular applications. Therefore, the objective of this work was to develop direct analytical procedures for Cr(VI) determination in the different steel coatings used for screws. Instead of working directly with screws, the optimisation of the procedures was carried out with metallic plates homogeneously coated to improve the data comparability. Extraction of Cr(VI) from the metallic parts was performed by sonication. Two extraction solutions were tested: a direct water extraction solution used in standard protocols and an ammonium/ammonia buffer solution at pH 8.9. The extracts were further analysed for Cr speciation by high-performance liquid chromatography (HPLC) inductively coupled plasma (ICP) atomic emission spectrometry or HPLC ICP mass spectrometry depending on the concentration level. When possible, the coatings were also directly analysed by solid speciation techniques (X-ray photoelectron spectroscopy, XPS, and X-ray absorption near-edge structure, XANES) for validation of the results. Very good results between the different analytical approaches were obtained for the sample of coating made up of a heated paint containing Zn, Al and Cr when using the extracting buffer solution at pH 8.9. After a repeated four-step extraction procedure on the same portion test, taking into account the depth of the surface layer reached, good agreement with XPS and XANES results was obtained. In contrast, for the coatings composed of an alkaline Zn layer where Cr(VI) and Cr(III) are deposited, only the extraction procedure using water allowed the detection of Cr(VI). To elucidate the Cr(VI) reduction during extraction at pH 8.9, the reactivity of Cr(VI) towards different species of Zn generally present in the coatings (metallic Zn and zinc oxide) was studied. The results showed that metallic Zn rapidly reduces Cr(VI), whereas this reaction is less evident in the presence of zinc oxide. Water was then retained for coatings containing metallic Zn.     

Surface synthesization of magnesium alloys for improving corrosion resistance and implant applications

In the field of biodegradable material, a new research area has emerged for magnesium (Mg) and its alloys because of its high biocompatibility and biomechanical compatibility. This review summarizes many important types of research that have been done on degradable coatings on magnesium and its alloys for various implant applications. When magnesium alloys come into contact with other metals, they have a low open circuit potential and are consequently prone to galvanic corrosion. When exposed to air or a humid environment, magnesium may rapidly oxidize and generate a thin layer of loose MgO. Its applications were limited due to these drawbacks. Different types of corrosion have been studied in relation to magnesium and its alloys. Several coating methods are described, split into conversion and deposition coatings based on the individual processing procedures employed. This paper covers the most recent advancements in the development of biodegradable Mg alloy coatings over the last decade, revealing that the corrosion resistance of Mg and its alloys increases in most of circumstances due to coatings. Corrosion rate, coating morphology, adhesion, and surface chemistry were identified and explored as significant elements affecting coating performance. Calcium phosphate coatings made by deposition or conversion processes established for orthopedic purposes are the focus of many investigations according to a review of the literature. More research is needed on organic-based biodegradable coatings to improve corrosion resistance. Improved mechanical qualities are also crucial for coating materials. Developing adequate methodologies for studying the corrosion process in depth and over time is still a hot topic of research.     

Antihypertensive drugs as an inhibitors for corrosion of aluminum and aluminum silicon alloys in aqueous solutions

The corrosion behavior of aluminum and three aluminum–silicon alloys in different concentrations of HCl solutions and its inhibition by antihypertensive drugs was studied using potentiostatic polarization measurements. As the acid concentration increases, the rate of corrosion increases. Aluminum is less susceptible to corrosion than any of Al–Si alloys. The inhibition efficiency of the drug compounds increases with their concentration up to a critical value. At higher additive concentrations the inhibition efficiency starts to decrease. The inhibitive action of these compounds is due to their formation of insoluble complex adsorbed on the metal surface. The adsorption follows Langmuir adsorption isotherms. It was found that the drugs compounds provide protection to Al and Al–Si alloys against pitting corrosion by shifting the pitting potential to more positive direction until critical drug concentrations (250 ppm). After this critical concentration the inhibition against to pitting corrosion starts to decrease.     

Simple preparation routes for corrosion protection hybrid sol‐gel coatings on AA 2024

In recent years, many hybrid inorganic‐organic systems have been proposed in order to replace the traditional conversion coatings on metals like aluminum, and some results have been promising. However, many proposed solutions are based on complicated processes which are not easy to be adapted to industrial scale. The aim of this study was to establish a simple process leading to the production of highly efficient corrosion protective hybrid sol‐gel coating systems for the aluminum alloys as replacement for the highly hazardous conventional chromate conversion coatings. Hybrid coatings have been realized by means of the sol‐gel process. CeO₂ and ZnO have been introduced as dispersions of nanoparticles in the system and used as corrosion inhibitors. The aim of this work was to obtain pore‐free coatings with increased barrier properties using nanoparticles that possess the double function of pore fillers and corrosion inhibitors. The proposed processes led to coating materials with good adherence to the aluminum substrate and an extremely long life in the accelerated neutral salt spray test according to DIN ISO 9227. Electrochemical impedance spectroscopy approves these results by high impedance values in the low‐frequency region of the Bode plot. Copyright © 2011 John Wiley & Sons, Ltd.     

Anticorrosive cerium-based coatings prepared by the sol–gel method

The development of efficient anti-corrosion and environmentally friendly coating systems are needed for the replacement of the highly toxic Cr-based conversion coatings for corrosion protection of aluminum alloys. In this study, we demonstrate that the direct application of ceramic cerium-based sol–gel coatings to AA7075-T6 substrates produces high-performance anti-corrosion layers. Electrochemical experiments and analyses of the microstructure demonstrate that the protective layers are very efficient for the passivation of the alloy surfaces operating as both passive and active barrier for corrosion protection.     

Spontaneous electrochemical transport reactions in ionic and ionic-electronic salt melts: The production of diffusion coatings

Extensive material concerning the interaction of metals in ionic and ionic-electronic salt melts is presented. The mechanism and character of the phenomenon of the directed spontaneous transport of metals by their ions in salt melts are established. Examples of application of this phenomenon for depositing diffusion coatings on metals and alloys (by aluminum, beryllium, boron, zinc, titanium, chromium, silicon, and so on, as well as by two-component coatings) are presented.     

Powder coatings for corrosion protection

Powder coatings found a wider use in corrosion protection of steel structure. In Europe very often double-layer systems are used, based on an adhesion promoting epoxy (EP) primer and a weathering stable top coat, mostly polyester (SP) sometimes EP/SP-hybrid powders. An interesting development is the use of zinc filled EP powders as primer to offer a cathodic protection to the steel surface. Powder systems with and without zinc were compared to proved coating systems based on liquid paint materials, where powder coating systems showed results comparable to these systems. Besides many advantages of powder coatings for corrosion protection there are still some problems. The workshops carring out the powder coating have to be in control of the surface pretreatment like chromating, but espescially phosphating and the work with the chromate-free pretreatment methods for galvanized steel. As always in the field of corrosion protection it is the surface pretreatment and preparation which determines the quality of the whole coating system decisively. This problem can be solved by appropriate working. In some years the problem with the general maintenance of powder coatings after weathering and ageing will be actual. This problem should be solved because of the homogeneous coatings on larger areas. Of importance will be the adhesion on the old coating and the appearance of the maintenance coating. The touch up of smaller parts as transport damages will be much more difficult in order to the appearance.     

The future of aluminum chemistry

This article represents a survey of current aluminum chemistry and some predictions regarding what type of aluminum chemistry will be conducted in the year 2000 and after. Because of the abundance and availability of aluminum in the earth, research incorporating this element will always be of importance to applications that impact on daily life. Indeed, applied chemistry is the primary goal of most aluminum research. It is likely that three broad areas of aluminum chemistry, catalysis, materials synthesis, and biological studies, will see substantial activity in the future. The use of aluminum in materials will continue in step with the growth of materials science, in general. In contrast, the use of aluminum compounds in catalysis and in effecting synthetic transformations will see a spectacular increase. This is a result of an increased understanding of the chemistry of aluminum, and the availability of a wide range of compounds containing aluminum which was been achieved over the past few decades during a period of increased attention to Main Group chemistry. In the coming years a clear understanding of the influence of aluminum on biological systems will almost certainly be obtained based upon the quality and amount of effort that has focused on this area in recent times.     

Metal corrosion induced by microbial activity – Mechanism and control options

Microbe-influenced material damage is the result of contributions from different types of microbes and their physiological activity. This fact makes the understanding of microbial corrosion very difficult. Another interesting fact is that the biofilms formed by the bacterial action inhibit or promote the biocorrosion of metals depending on the local environmental conditions. A slight change in the living conditions such as nutrient composition, oxygen concentration, light, and temperature can alter the behavior of the microbial population from non-corrosive to aggressively corroding. The metabolic activity of certain bacterial strains and the biofilm produced by them helps to control biocorrosion. The use of bioengineered bacterial strains has also been found to offer promising results in biocorrosion control. The most widely practiced biocorrosion mitigation practices include the application of protective coatings and the use of biocides. Recently, incorporating the corrosion protective functional layers on the metal surface via polymerization reactions has gained importance. This review provides information on the type of microorganisms causing the biocorrosion, their mechanism of action, and the factors that influence the corrosion rate. The development and involvement of the biofilm in corrosion have also been discussed in detail. The techniques available for the control of biocorrosion have also been explored.     

Formation and properties of composite coatings on aluminum alloys

A study was made into the morphology, composition, and electrochemical and mechanical properties of protective composite coatings on various aluminum alloys, including those doped with Sc, Cu, and Ni. It was established that protective coatings significantly increase the corrosion resistance of the alloys in a 3% NaCl solution. Composite coatings produced by triple dip coating in an superdispersed polytetrafluoroethylene suspension have unique corrosion-resistance properties, reducing the corrosion current density for all the protected alloys to 3.1 × 10^–11–4.0 × 10^–12 A/cm², which is more than three orders of magnitude lower than that for coatings formed by plasma electrolytic oxidation and five orders of magnitude lower than that for alloys without coating.     

Development of analytical procedures for determination of total chromium by quadrupole ICP–MS and high-resolution ICP–MS,and hexavalent chromium by HPLC–ICP–MS,in different materials used in the automotive industry

A European directive was recently adopted limiting the use of hazardous substances such as Pb, Hg, Cd, and Cr(VI) in vehicle manufacturing. From July 2003 a maximum of 2 g Cr(VI) will be authorised per vehicle in corrosion-preventing coatings of key components. As no standardised procedures are available to check if produced vehicles are in agreement with this directive, the objective of this work was to develop analytical procedures for total chromium and Cr(VI) determination in these materials. The first step of this study was to optimise digestion procedures for total chromium determination in plastic and metallic materials by inductively coupled plasma mass spectrometry (ICP–MS). High resolution (HR) ICP–MS was used to examine the influence of polyatomic interferences on the detection of the ⁵²Cr⁺ and ⁵³Cr⁺ isotopes. If there was strong interference with m/z 52 for plastic materials, it was possible to use quadrupole ICP–MS for m/z 53 if digestions were performed with HNO₃+H₂O₂. This mixture was also necessary for digestion of chromium from metallic materials. Extraction procedures in alkaline medium (NH₄⁺/NH₃ buffer solution at pH 8.9) assisted by sonication were developed for determining Cr(VI) in four different corrosion-preventing coatings by HPLC–ICP–MS. After optimisation and validation with the only solid reference material certified for its Cr(VI) content (BCR 545; welding dusts), the efficiency of this extraction procedure for screw coatings was compared with that described in the EN ISO 3613 standard generally used in routine laboratories. For coatings comprising zinc and aluminium passivated in depth with chromium oxides the extraction procedure developed herein enabled determination of higher Cr(VI) concentrations. This was also observed for the screw covered with a chromium passivant layer on zinc–nickel. For coating comprising a chromium passivant layer on alkaline zinc the standardized extraction procedure was more efficient. In the case of painted metallic plate, because of a reactive matrix towards Cr(VI), its extraction without degradation was difficult to perform.     

Sealing Anticorrosion Pastes for Resistant Spot Welding of Aluminum Alloys

This article investigates the application of PSP-2M and KSP-2AK pastes modified by Laproxid 603 for protection of the internal cavity of welding overlap of aluminum alloys. It has been demonstrated that, upon resistant spot welding of 1913 and 1370 aluminum alloys over such modified coatings, the weld joints are characterized by superior mechanic and corrosion properties.     

Application of laser micro- and nanotexturing for the fabrication of superhydrophobic corrosion-resistant coatings on aluminum

A new efficient method for the fabrication of corrosion-resistant composite superhydrophobic coatings on aluminum and its alloys is presented. The laser micro- and nanotexturing of the surface combined with the deposition of a hydrophobic agent makes it possible to obtain superhydrophobic coatings with unique properties on aluminum materials. The complex studies by electrochemical methods and wettability analysis showed that the proposed type of coatings is characterized by very high resistance to corrosion, including pitting resistance, and by the durability of the superhydrophobic state upon prolonged contact with aqueous chloride-containing media.     

Using capillary electrophoresis to study the chemical conditions within cracks in aluminum alloys

The environment-assisted cracking (EAC) susceptibility of some aluminum alloys used for airplane structural components currently limits their use in the peak strength condition. Understanding the mechanism of EAC will facilitate the development of crack-resistant alloys with optimum mechanical properties. One component towards understanding the fundamental processes responsible for EAC is a comprehensive knowledge of the chemical conditions within cracks. The present work uses capillary electrophoresis (CE) to quantify the crack chemistry in order to provide insight into the nature of the mechanism controlling cracking. The highly restricted geometry of cracks in metals means that a crack typically contains less than 10 μl of solution. The high mass sensitivity combined with the inherently robust nature of CE makes it an ideal analytical technique for this application. Complicating factors in the accurate determination of the crack environment include high levels of sodium present from the test solution. Low sample volume and analyte matrix complexity necessitated the development of specific sampling, extraction and analysis methods. Analysis of the crack solutions in EAC-susceptible material revealed high levels of Al³⁺, Mg²⁺, Zn²⁺, and Cl⁻ near the crack tip. Cations arise from the anodic dissolution of the alloy, whereas chloride ingress from the external environment occurs to maintain solution electroneutrality within the crack. In contrast, EAC-resistant material exhibited significantly lower concentrations of dissolution products.     

Coprecipitation as a means of separation in substoichiometric isotope dilution analysis

Chromium has been determined by isotope dilution in artificial standards and in standard alloys using the substoichiometric principle. As a substoichiometric reaction the reduction of Cr(VI) to Cr(III) was used, followed by separation of these species by coprecipitation of the trivalent chromium on a Ti(OH)₄ precipitate. For amounts smaller than 1 μg the standard method had to be modified owing to spontaneous reduction of hexavalent chromium in the solution. Interferences from other metals, if they occur, can be easily overcome. The method is simple and inexpensive.     

EIS investigation of a Ce-based posttreatment step on the corrosion behaviour of Alclad AA2024 anodized in TSA

In the aircraft industry, anodizing and posttreatment steps use Cr (VI) compounds, which, despite offering good corrosion resistance and self-healing properties, are highly toxic and carcinogenic. Ce compounds are recognized as efficient corrosion inhibitors for Al alloys, and several works report self-healing ability for these chemicals. In this investigation, the corrosion resistance of Alclad AA2024-T3 alloy anodized in tartaric-sulphuric acid (TSA) bath and posttreated in a solution comprising cerium nitrate without and with hydrogen peroxide was evaluated. The purpose is to investigate the potentiality of using hydrothermal treatment in Ce nitrate solution as candidate to replace Cr (VI) posttreatment. The aim is to provide a posttreatment step which, while improving the corrosion resistance, does not plug the mouths of the pores maintaining the adhesion properties of the porous anodic layer. Microstructural characterization was carried out by SEM-EDS whereas corrosion resistance was evaluated by EIS. The surface analysis showed that the posttreatments, all performed at 50°C, kept the open structure of the pores. EIS analysis showed that the posttreatments performed in the H₂O₂ solution for short immersion times were the most effective in improving the corrosion resistance of the samples, whereas electrical equivalent circuit (EEC) fitting of the data indicated sealing of the porous layer during the immersion of the different samples in the test solution. SEM-EDS analysis of the samples posttreated in the H₂O₂ containing solution, prior and after the corrosion test, showed the presence of Ce oxy-hydroxide randomly deposited on the sample surface, indicating that Ce could be incorporated/stored in the anodic layer.     

The preparation of supported ionic liquids (SILs) and their application in rare metals separation

This review summarizes the preparation methods of support ionic liquids (SILs) and their applications in rare metals separation. The rare metals separation includes the recovery of high value metal ions and the removal of heavy metal ions from wastewater. SILs can be used as a kind of highly efficient multifunctional separation materials. The preparation methods of SILs include chemical immobilization technique in which ILs moieties are supported on solid supports via covalent bonds and physical immobilization techniques in which ILs are immobilized on solid supports via physical method such as simple im- pregnation, sol-gel method. According to the difference of solid supports, this review summarizes the application of polymer supported ionic liquids (P-SILs), silica based material supported ionic liquids (SM-SILs) and membrane supported ionic liq- uids (M-SILs) in rare metals separation. P-SILs and SM-SILs prepared by chemical method with N-methylimidazolium group can be used as highly efficient anion exchangers with high thermal stability and good chemical stability for adsorption of Cr(VI), Re(VII), Ce(IV). P-SILs prepared via simple impregnation afforded IL functionalized solvent impregnated resins (SIRs) which showed high separation efficiency and selectivity in the separation of rare earths(III) (REs(III)). SM-SILs prepared via sol-gel method with IL doped in the support as porogens or extractant show high removal efficiencies and excellent stability for the separation of RE(III), Cr(III) and Cr(VI). M-SILs with IL as plasticizer or carrier show improved stability, high perme- ability coefficient and good selectivity for Cr(VI) transport. Different supports and different supporting methods were suffi- ciently compared. Based on the different practical application, different forms of SILs can be prepared for separation of rare metals with high separation efficiency and selectivity.     

A quantitative determination of the polymerization of benzoxazine thin coatings by time-of-flight secondary ion mass spectrometry

Phenol-paraphenylenediamine (P-pPDA) benzoxazines exhibit excellent barrier properties, adequate to protect aluminum alloys from corrosion, and constitute interesting candidates to replace chromate-containing coatings in the aeronautical industry. For the successful application of P-pPDA coatings, it is necessary to decrease the curing temperature to avoid the delamination of the coating while preserving the mechanical properties of the alloy, as well as the barrier properties of the coating. However, decreasing the curing temperature leads to less polymerized films, the extent of which requires a quantitative assessment. While the conversion rate of the polymerization reaction is commonly evaluated for bulk samples using differential scanning calorimetry (DSC), a tool for its evaluation in thin films is missing. Therefore, a new approach was developed for that matter using time-of-flight secondary ion mass spectrometry (ToF-SIMS). The relation between the SIMS data integrated from inside thin films and the DSC results obtained on bulk samples with the same curing cycle allowed to calibrate the SIMS data. With this preliminary calibration of the technique, the polymerization of P-pPDA coatings can be locally determined, at the surface and along the depth of the coating, using dual-beam depth profiling with large argon cluster beam sputtering.     

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.