Corrosion protection of carbon steel using a combination of Zr conversion coating and subsequent zinc-rich silicate coating with a flake ZnAl alloy

To improve the corrosion protection properties of zinc-rich silicate coatings on steel, zirconium pretreatment loaded with (3-aminopropyl)triethoxysilane (APTES) 0.025 % (v/v) and the partial replacement of spherical zinc by flake ZnAl alloy were investigated. DC polarization and electrochemical impedance spectroscopy (EIS) show that the zirconium pre-treated layer containing APTES improves the corrosion protection of the bare steel. Zinc-rich silicate coatings containing flake ZnAl with and without pretreatment were evaluated by EIS, salt spray test and pull-off test. Pretreatment with a zirconium conversion layer reduces corrosion products and adhesion loss (from 16.53% to 12.54%) while the performance of corrosion protection significantly increased from 2003 Ω.cm² to 2640 Ω.cm² in comparison with the non-pretreated samples. The results show that flake ZnAl pigment (5 wt%) significantly improves corrosion resistance and prolongs the duration of cathodic protection of zinc-rich silicate coatings.     

Growth behaviour of cerium-based conversion coating on Zn-5%Al alloy

Cerium-based conversion coatings were deposited on a Zn-5%Al alloy by immersing the alloy in cerium nitrate aqueous solutions with various immersion times. The growth behaviour of the cerium-based conversion coating on the Zn-5%Al alloy was investigated by the electrochemical impedance spectroscopy (EIS), SEM, energy dispersive spectroscopy (EDS), and XPS techniques. The results reveal that the coating mainly consists of ZnO, Zn(OH)₂, Ce(OH)₄, Ce(OH)₃, CeO₂, and Ce₂O₃. The growth of the cerium-based conversion coating is accompanied by metal dissolution. The dissolution mainly occurs on the η-Zn surface of the phase boundary and continues to extend to the Zn-rich phase as the coating grows. EIS results show that with increasing immersion time, the corrosion resistance of the Ce conversion coating gradually increases in the early growth stage and then decreases when the cracks appear.     

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.     

Zn-Al-[V10O28]6-双层氢氧化物掺杂对LY12铝合金表面溶胶-凝胶涂层性能的影响

采用共沉淀法制备Zn-Al-[V₁₀O₂₈]^6-双层氢氧化物(以下简称LDH-V), 研究不同添加浓度(0.0、0.25×10^-3、0.75×10^-3、1.5×10^-3、3.0×10^-3 mol·L^-1)的LDH-V对LY12 铝合金溶胶-凝胶涂层形貌、耐蚀性的影响. 采用扫描电子显微镜(SEM)和傅里叶变换红外(FTIR)光谱研究LDH-V对涂层形貌和结构的影响. 运用中性盐雾实验对涂层进行耐蚀性评估. 利用电化学方法对涂层在0.05 mol·L^-1的NaCl 溶液中的腐蚀行为进行研究. 探讨加入LDH-V后溶胶-凝胶涂层的耐蚀机理. 结果表明, 一定量LDH-V的加入不仅可以提高溶胶-凝胶涂层的耐蚀性能, 还可对涂层被破坏区域进行自修复, 起到延缓铝合金基体腐蚀的作用. 然而, 当LDH-V的添加溶度超过一定值时, 会破坏涂层的完整性并降低涂层的腐蚀防护性能. 实验结果表明LDH-V最佳的添加浓度为1.5×10^-3mol·L^-1.     

Corrosion behavior of electroless Ni–P/TiO2 nanocomposite coatings

Composite Ni–P/nano‐TiO₂ coatings were prepared by simultaneous electroless deposition of Ni–P and nano‐TiO₂ on a low carbon steel substrate. The deposition was carried out from stirred solutions containing suspended nano‐TiO₂ particles. The Ni–P and Ni–P/nano‐TiO₂ coatings before and after heat treatment were characterized by X‐ray diffraction, scanning electron microscopy and energy dispersive X‐ray spectroscopy. The micro‐structural morphologies of the coatings significantly varied with the nano‐TiO₂ content. The corrosion resistance of as‐plated and heat‐treated Ni–P and Ni–P/nano‐TiO₂ coatings was investigated by anodic polarization, Tafel plots and electrochemical impedance spectroscopic (EIS) studies in 3.5% NaCl solution. Ni–P/nano‐TiO₂ coating exhibited superior corrosion resistance over Ni–P coating. Copyright © 2015 John Wiley & Sons, Ltd.     

Improve Corrosion Resistance of Zircaloy by Copper–Graphene Nanocomposite Coatings

In this study, the corrosion behavior of Zircaloy was investigated in the presence and absence of copper–graphene nanocomposites coating. The coating was prepared employing Hummers’ and electrochemical reduction methods. The morphology of copper–graphene nanocomposites coating was studied using scanning electron microscopy (SEM). Corrosion behavior was investigated employing dynamic polarization and electrochemical impedance spectroscopy (EIS) tests in a solution containing lithium hydroxide (LiOH), boric acid (H₃BO₃), and deionized water. The results showed that corrosion resistance of Zircaloy increased with introduction of copper–graphene nanocomposites coatings. The lowest corrosion rate was attained in the Zircaloy with copper–graphene nanocomposites coating (corrosion rate: 0.040 mm/year). An approximately 20 times decrease in the corrosion rate was observed in the Zircaloy with copper–graphene nanocomposites coating when compared to the un-coated Zircaloy (corrosion rate: 0.831 mm/year).

     

Electrochemical testing practices of environmentally friendly aerospace coatings for corrosion performance assessment

Hexavalent chromium has been successfully employed for corrosion protection purposes in aerospace coatings for decades. However, legislation will restrict the use of Cr⁶⁺ in the future and therefore the aerospace sector needs to identify alternative environmentally friendly coatings for corrosion protection. Before implementation of newly developed systems into actual components is possible, rigorous and time-consuming testing practices are required to ensure the new systems can achieve the strict aerospace standards requirements. The emerging number of coating systems being developed, and the vast research conducted on the subject worldwide, make the selection of suitable replacements for industrial application challenging. In this work, differently pretreated aluminium AA2024 alloy surfaces are coated with conventional Cr⁶⁺ containing coating and compared with a number of industrial alternative coatings. Corrosion performance is assessed by real-time imaging while immersed, by electrochemical impedance spectroscopy (EIS), and by standardised salt-spray testing (SST). Results reveal that the performance ranking acquired by SST can be readily replaced by short-term immersion tests, and the time to failure in SST can be estimated from key corrosion indicators arising from EIS measurements at specific immersion times.     

Electrochemical corrosion behaviors and corrosion protection properties of Ni–Co alloy coating prepared on sintered NdFeB permanent magnet

In this study, a protective Ni–Co alloy coating was prepared on sintered NdFeB magnet applying electrodeposition technique. A pure nickel coating was also studied for a comparison. The microstructure, surface morphologies, and chemical composition of coatings were investigated using X-ray diffraction, scanning electron microscope, and energy dispersive spectroscopy, respectively. The corrosion protection properties of coatings for NdFeB magnet in neutral 3.5 wt.% NaCl solutions were evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) techniques. The microstructure and surface morphologies analysis showed that the addition of cobalt element into matrix metal Ni altered the preferential orientation of pure nickel coating from (2 0 0) crystal face for pure nickel coating to (1 1 1) crystal face for Ni–Co alloy coating, and made the surface morphologies more compact and uniform due to the grain-refining. The results of potentiodynamic polarization test showed that compared with pure nickel coating, Ni–Co alloy coating exhibited much nobler corrosion potential (E _corr) and lower corrosion current density (j _corr), indicating better anticorrosive properties. The long-term immersion test by dint of EIS indicated that the Ni–Co alloy coating still presented high impedance value of 1.9 × 10⁵ Ω cm² with the immersion time of 576 h indicating the excellent anticorrosive properties, and corrosion protection properties of nickel coating for NdFeB magnet practically disappeared with the immersion time of 144 h, which also indicated that the Ni–Co alloy coating provided better corrosion protection properties for the NdFeB magnet compared with nickel coating.     

Phosphatation of iron powder metallurgical samples for corrosion protection

Recently, powder metallurgy methods have been used widely for industrial purposes. In this work, powder-metallurgically produced samples were selected for zinc phosphate coating. Zinc phosphate coating was performed at 50 and 70 °C for 20 min in a bath containing 10 g l^?1 ZnO, 25.5 g l^?1 H₃PO₄, 5.88 g l^?1 HNO₃, and 2 g l^?1 NaNO₃. The effect of temperature on the phosphating process has been studied. The structure and corrosion resistance of coats have been investigated using scanning electron microscopy (SEM) and electrochemical methods (polarization and EIS). Results show that an increase in temperature affects the crystalline structure of the coats. The formation of the zinc phosphate coat on the powder metallurgical samples significantly decreases the corrosion rate of the samples.     

尿素对土壤中碳钢微生物腐蚀的影响

采用失重、极化曲线和阻抗谱等方法研究了尿素对土壤中微生物腐蚀(MIC)的影响. 研究结果表明, 在接菌土壤中尿素加速碳钢的腐蚀, 而在灭菌土壤中抑制其腐蚀. 接菌土壤中由于硫酸盐还原菌(SRB)的存在,腐蚀产物中检测到FeS₂. 电化学阻抗谱(EIS)的结果表明, 在实验后期腐蚀过程由浓差极化控制.     

Corrosion resistance of zinc electrodeposited from acidic and alkaline electrolytes using pulse current

Corrosion resistance of zinc coatings was investigated in an accelerated corrosion test in a condensation chamber. Zinc was electrodeposited from alkaline and acidic electrolytes using direct current (DC) or pulse current (PC). The zinc coating was subsequently protected against corrosion with a chrome (III) layer. Morphology and structure of the coatings was investigated using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffraction analysis (XRD) before and after the corrosion test. Corrosion resistance of alkaline zinc coatings electrodeposited with DC and PC under test conditions was found to be comparable. The corrosion resistance of zinc coatings deposited from acidic electrolytes by PC was lower in comparison with corrosion resistance of zinc coatings deposited using DC. Presented at the 8th Conference on Solid State Chemistry, Bratislava, Slovakia, 6–11 July 2008.     

Evaluation of the corrosion resistance of electroless Ni-P and Ni-P composite coatings by electrochemical impedance spectroscopy

Electroless Ni-P composite coatings have gained a good deal of popularity and acceptance in recent years as they provide considerable improvement of desirable qualities such as hardness, wear, abrasion resistance, etc. The disagreement among researchers on the corrosion behaviour of these coatings warrants a thorough investigation. Among the various techniques available for the determination of corrosion resistance, electrochemical impedance spectroscopy (EIS) is considered to be superior as it provides not only an assessment of the corrosion resistance of different deposits but also enables the mechanistic pathway by which the deposits become corroded to be determined. The present investigation focuses on the evaluation of the corrosion resistance of electroless Ni-P and Ni-P-Si₃N₄, Ni-P-CeO₂ and Ni-P-TiO₂ composite coatings produced using an acidic hypophosphite-reduced electroless nickel bath, using EIS. The study makes evident that the same fundamental reaction is occurring on all the coatings of the present study but over a different effective area in each case. The charge transfer resistance of electroless Ni-P and Ni-P composite deposits are in the range 32,253–90,700 Ω cm², whereas the capacitances of these coatings are in the range 11–17 μF/cm². The improved corrosion resistance obtained for electroless Ni-P and Ni-P composite coatings is due to the enrichment of phosphorus on the electrode surface, which enables the preferential hydrolysis of phosphorus over that of nickel. The better corrosion resistance obtained for electroless Ni-P composite coatings can be ascribed to the decrease in the effective metallic area prone to corrosion. Among the three electroless Ni-P composite coatings, the corrosion resistance is in the following order: Ni-P-CeO₂=Ni-P-Si₃N₄>Ni-P-TiO₂. Electronic Publication     

WBE联合EIS技术研究缺陷涂层下金属腐蚀

用电化学阻抗谱(EIS)结合丝束电极(WBE)技术研究了缺陷涂层浸泡在3.5%(质量分数)NaCl溶液中的劣化过程.从浸泡开始到完好涂层鼓泡失效,缺陷涂层丝束电极阻抗响应一直是缺陷区电极腐蚀反应过程特征,而完好涂层的劣化过程和涂层下的腐蚀反应过程特征被"平均掉".根据电极表面的电流分布,结合阻抗谱技术实现了对表面任意局部阴极和阳极区阻抗测试.研究发现,浸泡开始时,缺陷涂层阴极电流和阳极电流均出现在缺陷区,随着腐蚀过程的发展,阳极电流仍然保持在缺陷区,但阴极电流逐渐向完好涂层下扩展.根据实验结果,对缺陷处和涂层下金属腐蚀反应发生发展的机理进行了深入讨论.     

电镀锌钛/锆基无铬化学转化膜的制备与耐蚀性能

借助优化钛/锆基化学转化工艺,在碱性无氰镀锌层基体上获得了环保型的无铬转化膜,并与铬酸盐彩色钝化膜作对比.中性盐雾试验、动电位极化和电化学阻抗谱测试结果表明:钛/锆基化学转化膜出现白锈时间为96 h,达到铬酸盐彩色钝化膜标准,且呈现出较低的腐蚀电流和较高的极化电阻,但钝化特性不如铬酸盐彩色钝化膜明显.     

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.     

Potential of zinc based-graphene oxide composite coatings on mild steel in acidic solution

This study introduces varying concentrations of graphene oxide (GO) as a filler into zinc chromate in forming composite coatings to improve the corrosion protection of mild steel. The purity of synthesized GO was inferred through the application of complementary characterization techniques, including FT-IR, XRD, Raman, SEM-EDX, and TEM analyses. GO doped zinc chromate coatings were deposited on the surface of mild steel through the brushing method. Electrochemical studies, i.e., electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PD) were conducted to elucidate the anticorrosion properties of the coated mild steel exposed to 0.5 ​M HCl solution. It was revealed that the highest anticorrosion protection was attained at low doping amount of 0.5% of GO with a corrosion rate of 0.036 mpy. Surface analyses revealed that incorporating GO into zinc chromate coating can effectively improve the anticorrosion properties and adhesion strength.     

Corrosion resistance of amorphous AlPO4 coating in salty atmospheres

The objective of the present study was to introduce a cost-effective and environmentally friendly coating to improve the corrosion resistance of the structures located in salt water. The coating solution, based on amorphous aluminum phosphate composition, was synthesized by sol–gel process and applied to AISI 304 stainless steel by dip coating technique. X-ray diffraction, scanning electron microscopy, and energy dispersive X-ray spectroscopy analyses were employed to investigate the phase composition and morphology of the coating. Corrosion behavior of the uncoated and coated samples was investigated using standard salt spray test, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS) in 3.5 wt.% NaCl solution. Salt spray test results for the bare substrate revealed a corrosion rate of six-time greater than that of the coated surface after 168 hr exposure time. Electrochemical test results declared that the amorphous AlPO₄ coating decreased the corrosion current density of the AISI 304 stainless steel by 10 orders of magnitude. Furthermore, according to the corresponding EIS measurements, the coated surface exhibited a superior anti-corrosion performance than uncoated sample. Overall, the results declared that the amorphous AlPO₄ coating could be a good choice for surface protection of stainless steel against electrochemical corrosion in salty environments.     

(NaPO3)6对AZ91D镁合金微弧氧化陶瓷层电化学腐蚀特性的影响

在Na2SiO3-KOH电解液体系中添加一定量的(NaPO3)6, 利用微弧氧化(MAO)技术在AZ91D 镁合金表面制备了原位生长的陶瓷层. 采用动电位极化和电化学阻抗谱(EIS)技术研究了添加(NaPO3)6前后, 制备的陶瓷层在3.5%(w) NaCl溶液中的室温电化学行为. 结果表明, 添加(NaPO3)6后, 陶瓷层的自腐蚀电位显著上升, 自腐蚀电流密度明显减小. 这主要是由于(NaPO3)6增加了反应过程中基体镁合金表面的“氧空位”和溶液中PO3-4的含量, 促使元素Mg在金属/膜层(M/F)界面上快速形成相应氧化物, 从而增加了陶瓷层的厚度和致密性. 根据电化学反应体系和陶瓷层的特殊结构, 建立了合理的等效电路, 并结合EIS 数据, 分析了添加(NaPO3)6提高陶瓷层耐电化学腐蚀性能的机理.     

Studies on electrodeposition of Zn–MoS<Subscript>2</Subscript> nanocomposite coatings on mild steel and its properties

Pure zinc and Zn–MoS₂ composite coatings were prepared by electrodeposition from zinc sulfate–chloride bath containing uniformly dispersed MoS₂ nanoparticles. The effect of MoS₂ on the deposition properties morphology, crystallographic orientation, and corrosion behavior were studied. The electrokinetic properties (zeta potential) and size distribution statistics in plating bath for the particles were evaluated using dynamic light scattering experiments. The Zn and Zn–MoS₂ deposition process was studied by linear polarization and cyclic voltammetry. Scanning electron microscopy, energy dispersive X-ray analysis, X-ray diffraction analysis, and potentiodynamic polarization measurements were used to characterize the coatings. The addition of MoS₂ to the electrolyte significantly changed the microstructure and crystallographic orientation of the zinc deposits and enhanced the corrosion resistance of the coatings. The morphological and electrochemical properties of the zinc coatings were observed to be significantly affected by the incorporation of MoS₂ particles into the zinc matrix.     

Enhanced corrosion protection performance with MWCNT dispersed epoxy coating prepared under supercritical CO2 assistance

The corrosion protection performance of epoxy coatings could be enhanced by incorporation of nanofillers such as MWCNT. However, a homogeneous dispersion of MWCNT in epoxy polymer is still a teasing challenge. Herein, we report an environmentally benign single‐step supercritical CO₂ processing method to improve the dispersion of MWCNT in epoxy matrix in order to achieve an effective anticorrosive coating. The executed approach provides a cluster‐free uniform distribution of MWCNT in epoxy matrix as characterized with UV‐visible spectroscopy, Fourier transforms infrared spectroscopy, X‐ray diffraction, and surface analysis. The anticorrosive characteristics of MWCNT/epoxy coating were studied in NaCl as well as in photodegraded dye medium through electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization measurements. We observed the remarkable corrosion of model metal substrate in photodegraded dye medium besides NaCl medium. In both mediums, the protection efficacy of MWCNT/epoxy coating was deduced from the stable impedance arcs in Nyquist plot and increased impedance modulus. The electrochemical impedance spectra were best fitted with equivalent circuits showing the higher values of pore resistance. Also, the MWCNT/epoxy coating exhibited a positive shift of corrosion potential and possessed a lower corrosion rate as compared with neat epoxy coating. More direct evidence of the excellent barrier properties for MWCNT/epoxy coating was visualized in SEM images. The obtained results implied that the superior dispersion of MWCNT into epoxy matrix significantly reduces the porosity of coating and inhibits the permeability of corrosive ions. We expect supercritical CO₂ assisted dispersion method can offer an efficient, cost‐effective, and industrially viable route to develop high performance protective coatings for varied commercialized applications.