Corrosion and wear resistance properties of multilayered diamond‐like carbon nanocomposite coating

Multilayered diamond‐like carbon (DLC) nanocomposite coating has been deposited on silicon and stainless steel substrates by combination of cathodic arc evaporation and magnetron sputtering. In order to make DLC coating adhered to metal substrate, a chromium interlayer has been deposited with constant bias voltage of −150 V applied to the substrate. Dense multilayered coating consists of metallic or nonmetallic and tetrahedral carbon (ta‐C) layers with total thickness of 1.44 μm. The coating has been studied for composition, morphology, surface nature, nanohardness, corrosion resistance, and tribological properties. The composition of the coating has been estimated by energy‐dispersive spectroscopy. Field‐emission scanning electron microscopy and atomic force microscopy have been used to study the surface morphology and topography. I_D/I_G ratio of ta‐C:N layer obtained from Raman spectroscopy is 1.2, indicating the disorder in the layer. X‐ray photoelectron spectroscopy studies of individual ta‐C:N, CrN, and Cr‐doped DLC layers confirm the presence of sp²C, sp³C, CrN, Cr₂N, and carbidic carbon, and sp²C, sp³C, and Cr carbide. Nanohardness studies show the maximum penetration depth of 70 to 85 nm. Average nanohardness of the multilayered DLC coating is found to be 35 ± 2.8 GPa, and Young's modulus is 270 GPa. The coating demonstrates superior corrosion resistance with better passivation behavior in 3.5% NaCl solution, and corrosion potential is observed to move towards nobler (more positive) values. A low coefficient of friction (0.11) at different loads is observed from reciprocating wear studies. Wear volume is lower at all loads on the multilayered DLC nanocomposite coating compared to the substrate.     

Inhibition effect of cerium in hybrid sol–gel films on aluminium alloy AA2024

Aluminium alloys such as AA2024 are susceptible to severe corrosion attack in aggressive solutions (e.g. chlorides). Conversion coatings, like chromate, or rare earth conversion coatings are usually applied in order to improve corrosion behaviour of aluminium alloys. Methacrylate‐based hybrid films deposited with sol–gel technique might be an alternative to conversion coatings. Barrier properties, paint adhesion and possibly self‐healing ability are important aspects for replacement of chromate‐based pre‐treatments. This work evaluates the behaviour of cerium as corrosion inhibitor in methacrylate silane‐based hybrid films containing SiO₂ nano‐particles on AA2024. Hybrid films were deposited on aluminium alloy AA2024 by means of dip‐coating technique. Two different types of coating were applied: a non‐inhibited film consisting of two layers (non‐inhibited system) and a similar film doped with cerium nitrate in an intermediate layer (inhibited system). The film thickness was 5 µm for the non‐inhibited system and 8 µm for the inhibited system. Film morphology and composition were investigated by means of GDOES (glow discharge optical emission spectroscopy). Moreover, GDOES qualitative composition profiles were recorded in order to investigate Ce content in the hybrid films as a function of immersion time in 0.05 M NaCl solution. The electrochemical behaviour of the hybrid films was studied in the same electrolyte by means of EIS technique (electrochemical impedance spectroscopy). Electrochemical measurements provide evidence that the inhibited system containing cerium displays recovery of electrochemical properties. This behaviour is not observed for the non‐inhibited coating. GDOES measurements provide evidence that the behaviour of inhibited system can be related to migration of Ce species to the substrate/coating interface. Copyright © 2010 John Wiley & Sons, Ltd.     

Preparation and characterization of organic–inorganic hybrids and coating films from 3‐methacryloxypropylpolysilsesquioxane

3‐Methacryloxypropylpolysilsesquioxane (MA‐PS) was prepared by acid‐ or base‐catalyzed hydrolytic polycondensation of 3‐methacryloxypropyltrimethoxysilane (MAS). MA‐PS coating film was prepared by dip‐coating on organic, metal and inorganic substrates, including poly(ethylene terephthalate), aluminum, stainless steel, and glass. The coating films on poly(ethylene terephthalate) and glass showed high adhesive strength. The hardness of coating films increased with increasing heat treatment temperature, whereas they decreased with increasing H₂O/MAS molar ratio. The refractive index of coating films increased with increasing heat treatment temperature. In addition, flat and transparent free‐standing films (0.24–0.27 mm thickness) were prepared from MA‐PS that were crack‐free after heat treatment at 1000 °C. Copyright © 2001 John Wiley & Sons, Ltd.     

Electron field emission of iron and cobalt‐doped DLC films fabricated by electrochemical deposition

Using a simple electrochemical depositing process, iron and cobalt‐doped diamond‐like carbon (DLC) films were deposited on Si (100) substrates. The results showed that metallic elements were inhomogeneously doped into highly cross‐linking amorphous carbon matrix, forming the typical nanocrystalline/amorphous nanocomposite structure, and simultaneously the microsturcture of amorphous carbon was changed by the doping of metals. Field emission performance showed that the incorporation of iron and cobalt effectively decreases the threshold field from 13.5 V/µm to 8.0 V/µm and 6.5 V/µm, respectively, and a highest current density of the Co‐DLC film was about 1.2 mA/cm² at the electric field of 23.5 V/µm. Copyright © 2012 John Wiley & Sons, Ltd.     

The high‐temperature tribological properties of Si‐DLC films

The tribological properties of Silicon‐containing diamond‐like‐carbon (Si‐DLC) films, deposited by magnetron sputtering Si target in methane/argon atmosphere, were studied in comparison with diamond‐like‐carbon (DLC) films. The DLC films disappeared because of the oxidation in the air at 500 °C, whereas the Si‐DLC films still remained, implying that the addition of Si improved significantly the thermal stability of DLC films. Retarded hydrogen release from DLC film at high temperature and silicon oxide on the surface might have contributed to lower friction coefficient of the Si‐DLC films both after annealing treatment and in situ high‐temperature environment. Copyright © 2012 John Wiley & Sons, Ltd.     

Photopatternable substrate‐independent poly(glycidyl methacrylate‐ran‐2‐(acryloyloxy) ethyl 2‐methylacrylate) polymer films for immobilization of biomolecules

We report the synthesis and characterization of a photocrosslinkable copolymer containing reactive epoxy groups for binding biomolecules. The epoxide‐containing copolymer poly(glycidyl methacrylate‐ran‐2‐(acryloyloxy) ethyl 2‐methylacrylate) offers distinct advantages such as ease of application to various substrates, enhanced stability of the bound oligonucleotide, low autofluorescence, and the ability to be photopatterned allowing localization of the linkers. The copolymer uses pendant acryloyl groups to control the crosslinking without sacrificing the epoxide groups. The films were characterized using ellipsometry, atomic force microscopy, and fluorescence microscopy. The films on glass, silicon wafer, and stainless steel showed no appreciable degradation in water, tetrahydrofuran, and acetone for ～4 months. The surface topography for a given thickness of crosslinked film was dictated by the deposition conditions. A 16mer oligonucleotide was immobilized on the thin films. A linear relationship between the film thickness and amount of oligonucleotide immobilized was observed with a maximum signal‐to‐background ratio (S/B) of 225 for a 60‐nm‐thick film, a value 50% higher than the S/B for an epoxide monolayer. The crosslinked films maintained a high fluorescence signal following long aqueous washing which is appealing for biological microarrays, immobilizing proteins, and study of slow differentiating cells where stability of the scaffold is relevant. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 5826–5838, 2008     

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.     

High‐resolution resist for screen printing: application to direct fabrication of Ag circuit

High‐resolution screen printing was devised. New resist formulation contains a base polymer, which consists of acid‐labile tetrahydropyranyl‐protected carboxylic acid, hydroxyl, and methacrylic functions. As crosslinkers, multifunctional acrylates were employed. Photoacid generators were used for pattern formation. A 10‐µm feature size of resist on a screen plate was obtained on irradiation at 365 nm and followed by development on a stainless steel screen. Post‐exposure curing improved the mechanical characteristics of the resist patterns. A 13‐µm feature size silver circuit was successfully printed on poly(ethylene terephthalate) film without defect. Copyright © 2011 John Wiley & Sons, Ltd.     

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.     

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.     

Scanning force microscopy study of the morphology of spin‐cast molecular‐imprinted nylon thin films

The morphology of thin, selectively imprinted films of Nylon‐6 was investigated by scanning force microscopy. Four amino acids were used as template molecules in the spin‐cast films. Film thickness ranged from 2 µm to 500 nm, depending on the nylon and template concentration in the casting solution. The thin‐film properties, including the presence of nanometer‐ to micrometer‐sized pores, are clearly associated with the imprinting process. The larger features observed by scanning force microscopy are attributed to amino acid clustering during the casting process. Copyright © 2004 John Wiley & Sons, Ltd.     

An approach to differentiating between multi‐ and monolayers using MALDI‐TOF MS

Analysis and confirmation of monolayer film thickness on metal oxide surfaces has proven to be challenging. XPS and AFM have been used to investigate the monolayer formation. However, these techniques are difficult to access and/or determine the composition of the organic molecules on the surfaces. Here we demonstrate the ability of MALDI‐TOF to characterize long alkyl chain phosphonic acid molecules in thin films on titanium, iron and stainless steel. These systems are known to be stable, strongly adhered films. The thin films were characterized by IR, AFM, contact angle measurements and the results were confirmed by MALDI‐TOF. Moreover, the MALDI‐TOF was used to differentiate between mono‐ and multilayers on planar surfaces. Copyright © 2007 John Wiley & Sons, Ltd.     

Thickness determination of TiN and TiAl coatings on steel substrates using X‐ray diffraction method and their composition measurements by GD‐OES

This paper presents a nondestructive X‐ray diffraction method for the accurate determination of thicknesses of polycrystalline TiN and amorphous‐like TiAl coatings deposited by DC magnetron sputtering onto thick polycrystalline stainless steel and carbon steel substrates. This method relies on the measurement of intensity loss of a substrate reflection caused by the deposition of the coating. The uncertainty of the thickness measurements by the X‐ray diffraction depends on the mass absorption coefficient of the coating material and the quality of the collected diffraction patterns. For the coatings considered, thicknesses determined by the X‐ray diffraction method show very good agreement with the thickness values measured by scanning electron microscopy and ball crater techniques.     

An Electrochemical Study on the Corrosion Inhibition of Stainless Steel by Polyaniline Film

Polyaniline(PANI)film was electrosynthesized on 304 stainless steel by cyclic voltammetry using aqueous oxalic acid as supporting electrolyte.The potential sweep rates were changed to achieve the PANI film with different thickness and structures.Protective properties of the PANI film for corrosion of stainless steel in 3% NaC1 aqueous solution were investigated by monitoring potentiodynamic polarization curves and electrochemical impedance spectroscopy(EIS).The results showed that the PANI film which was formed with lower sweep rate led to more positive shift of corrosion potential and greater charge transfer resistance,reflecting higher inhibition for corrosion of the stainless steel.     

Effects of anodic oxidation on corrosion properties of Al coating by arc spraying in seawater

A layer of Al coatings was prepared on the S355 steel by arc spraying, which was conducted by anodic oxidation treatment; the morphologies, chemical element compositions and phases of Al coating, and anodic oxide layer were analyzed with field emission scanning electron microscope (FESEM), energy dispersive spectrometer (EDS) and X‐ray diffraction (XRD), respectively. The corrosion protections of Al coating before and after anodic oxidation were discussed with a seawater immersion test; the corrosion resistance mechanisms of Al coating and anodic oxide layer in the seawater were also investigated. The results show that the thickness of Al coating is about 300 µm by arc spraying, the sample surfaces become loose after seawater immersion corrosion and Cl^? and O^2? penetrate into the substrate from the cracks, destroying the binding properties of coating–substrate, and the coating fails. After anodic oxidation, the oxide layer is formed in the surface of Al coating with the thickness of about 30 µm; the corrosion products are mainly composed of Al(OH)₃, which barraged the holes caused by seawater corrosion. The corrosion cracks are formed during the corrosion, while the number and depth of cracks decrease obviously after anodic oxidation treatment. The corrosion of Al coating becomes the local corrosion after anodic oxidation treatment, and the grains are smaller, which are easily nucleated to form a new corrosion resistance layer. Copyright © 2015 John Wiley & Sons, Ltd.     

NLO‐active maleimide copolymers with ­high glass transition temperatures

We synthesized some novel rigid NLO‐active maleimide copolymers bearing DR‐1 moieties ( PMPD , PHSD and PHND ). All copolymers exhibited high T_g's (190～197 °C), good solubilities for common solvents and excellent film‐forming properties. Dependence of film thickness on the d₃₃ value for the poled copolymer films induced by corona poling was investigated and it was demonstrated that in less than thickness of 0.3 µm decrease of the thickness gives rise to remarkable increase in the d₃₃ value. The poled copolymer films exhibited large d₃₃ values (270 × 10^?9 esu (film thickness 0.13 µm) for PMPD , 290 × 10^?9 esu (0.12 µm) for PHSD and 350 × 10^?9 esu (0.08 µm) for PHND ) as well as large r₃₃ values (51.0 pmV^?1 for PMPD and 60.4 pmV^?1 for PHND ) which are significantly large compared to the value of LiNbO₃ (31 pmV^?1) as a typical EO material. The d₃₃ values of the poled copolymers were kept constant even after standing 1000h at 80 °C, although a small decrease was observed at an initial stage. Further, the d₃₃ values did not change up to ca. 123 °C upon heating at the rate of 10 °C/min in all cases. Copyright © 2002 John Wiley & Sons, Ltd.     

Properties of nitrocellulose‐coated and polyethylene‐laminated chitosan and whey films

Chitosan (chitosan acetic acid salt) and whey (65% protein) films were coated with a nitrocellulose lacquer or laminated with polyethylene to enhance their water resistance and gas barrier properties in humid environments. The barrier properties were measured by the Cobb₆₀ test and water‐vapor (100% relative humidity) transmission and oxygen (90% relative humidity) permeability tests. Mechanical properties were obtained with tensile tests. Packaging properties were studied with crease and folding tests. The Cobb₆₀ test revealed that the coated films were resistant to liquid water, at least for a short exposure time, if the coating thickness was at least 10–17 μm. Water‐vapor transmission rates comparable to those of polyethylene‐laminated films were obtained for coated chitosan at a coating thickness of 5–7 μm. The coated films possessed low oxygen permeability despite the high humidity. Coated films dried for 3 weeks showed oxygen permeabilities at 90% relative humidity that were similar to values for dry ethylene‐co‐vinyl alcohol at 0% relative humidity. The lacquer partly penetrated the whey films, and this led to excellent adhesion but poor lacquer toughness. The lacquer coating on chitosan was tougher, and it was possible to fold these films 90° without the coating fracturing if the coating thickness was small. The coated whey films were readily creasable. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 985–992, 2001     

Controlled,micro‐scale film formation of waterborne dispersions

The film formation on a micro‐scale of latex material is described. Waterborne polymer dispersions dried below their Tg are treated by laser or direct heat treatment by means of a tip (diameter 5 µ m) of a micro thermal analysis apparatus (µ ‐TA). Both methods give a linewidth, line thickness and dot‐sizes in the micron range. The layer thickness decreases during fusion of the particles because of the loss of voids during film formation. Non treated areas can be washed away selectively. Laser treatment gives a more smooth surface than direct thermal treatment with a µ‐TA tip. Copyright © 2001 John Wiley & Sons, Ltd.     

Influence of zirconium doping on the growth of apatite and corrosion behavior of DLC‐coated titanium alloy Ti–13Nb–13Zr

Ti–13Nb–13Zr was coated with diamond‐like carbon (DLC) and zirconium‐doped DLC by plasma‐enhanced chemical vapor deposition and sputtering. The corrosion current of the substrate is not affected after coating, and corrosion potential shifts towards nobler values in Hanks' solution. Electrochemical impedance spectroscopy studies show that Zr‐DLC samples behave like an ideal capacitor. Field emission scanning electron microscopy (FESEM) images after 7 days of immersion show absence of apatite on DLC‐coated sample and its presence on Zr‐doped DLC, but to a lesser extent as compared with that on the uncoated substrate. XPS and Energy‐dispersive X‐ray spectroscopy (EDS) of samples immersed in Hanks' solution show presence of calcium, phosphorous and oxygen in hydroxide/phosphate form on the substrate and Zr‐DLC. Copyright © 2013 John Wiley & Sons, Ltd.     

Monte‐Carlo simulation of spatial distribution of characteristic x‐rays in multi‐film targets: source size of Al Kα x‐rays in W/Al film targets

A Monte‐Carlo simulation approach has been applied to describe the spatial distribution of characteristic x‐rays in W/Al film targets of different combinations of film thicknesses for the optimal design of a small‐sized x‐ray source having a high x‐ray intensity. The result has led to optimal combinations of W and Al film targets for 100 kV electrons, e.g. W(1 µm)/Al(20 µm), W(3 µm)/Al(15 µm) and W(5 µm)/Al(8 µm). These Al/W targets could be used as x‐ray sources for a medical instrument currently under development. Copyright © 2004 John Wiley & Sons, Ltd.