Influence of surface treatments in the initial stages of anodizing Al–Ag alloys in neutral electrolytes

Using voltage-time responses and cyclic voltammetry, the initial stages of anodizing of Al–2.1 at.% Ag and Al–4 at.% Ag alloys are shown to depend upon the heat treatment of the alloys and the pre-treatment of the alloy surfaces. Chemical polishing of solution-treated alloys leads to relatively uniform anodic oxidation on a relatively smooth alloy surface, in the absence of significant effects of coarse, silver-rich intermetallics. In contrast, losses of current to oxygen generation arise for the roughened alloy surface from mechanical polishing. With ageing, secondary reactions at the relatively silver-rich intermetallics are more prevalent, although the effects on the voltage-time response depend upon the balance between processes occurring on the matrix and intermetallic regions, including film growth, oxygen generation within the anodic film, film damage due to release of oxygen, dissolution of silver species and re-growth of damaged film.     

Tracer studies of anodic films formed on aluminium in malonic and oxalic acids

Using a tungsten-containing layer, incorporated into sputtering-deposited aluminium, as a tracer, the growth of porous anodic films in malonic and oxalic acid electrolytes has been investigated using transmission electron microscopy, Rutherford backscattering spectroscopy and nuclear reaction analysis. Comparisons were also made with films formed in phosphoric acid electrolyte, which have been studied previously. The findings reveal a distortion of the tracer layer within the barrier region of the porous films, evident as a lagging of the tracer beneath the pores relative to that in the adjacent cell wall region. Further, the films are significantly thicker than the layer of metal consumed during anodizing and display smooth-sided pores. The anodizing behaviours are consistent with a major role for field-assisted flow of film material within the barrier layer in the development of the pores.     

Corrosion behaviour of mechanically polished AA7075‐T6 aluminium alloy

In the present study, the effects of mechanical polishing on the microstructure and corrosion behaviour of AA7075 aluminium alloy are investigated. It was found that a nano‐grained, near‐surface deformed layer, up to 400 nm thickness, is developed due to significant surface shear stress during mechanically polishing. Within the near‐surface deformed layer, the alloying elements have been redistributed and the microstructure of the alloy is modified; in particular, the normal MgZn₂ particles for T6 are absent. However, segregation bands, approximately 10‐nm thick, containing mainly zinc, are found at the grain boundaries within the near‐surface deformed layer. The presence of such segregation bands promoted localised corrosion along the grain boundaries within the near‐surface deformed layer due to microgalvanic action. During anodic polarisation of mechanically polished alloy in sodium chloride solution, two breakdown potentials were observed at ?750 mV and ?700 mV, respectively. The first breakdown potential is associated with an increased electrochemical activity of the near‐surface deformed layer, and the second breakdown potential is associated with typical pitting of the bulk alloy. Copyright © 2009 John Wiley & Sons, Ltd.     

Enrichment,incorporation and oxidation of copper during anodising of aluminium–copper alloys

Porous anodic oxides generated on copper‐containing aluminium alloys are less regular than anodic oxides generated on pure aluminium. Specifically, a porous oxide morphology comprising layers of embryo pores, generated by a cyclic process of oxide film growth and oxygen evolution, is generally observed. In this work, the relation between the oxidation behaviour of copper during anodising and the specific porous oxide film morphology was investigated by electrochemical techniques, transmission electron microscopy and Rutherford backscattering spectroscopy (RBS). It was found that the anodising potential determines the oxidation behaviour of copper, and the latter determines the porous oxide morphology. At low voltage, relatively straight pores with continuous cell walls were obtained on Al? Cu alloys, but selective oxidation of aluminium atoms resulted in the occlusion of copper‐containing metallic nanoparticles in the anodic film. At higher potentials, copper oxidation promoted oxygen evolution within the barrier layer, and generation of a less regular film morphology. RBS, performed on Al? Cu alloy specimens, revealed a high volume fraction of copper atoms in the anodic films generated at low potentials and a reduced amount of copper atoms in the anodic oxide films generated at high potentials. Copyright © 2009 John Wiley & Sons, Ltd.     

Effect of magnesium and titanium on the cathodic behaviour of aluminium in nitric acid

Cathodic polarization of aluminium and Al–0.18 wt.% Mg and Al–0.08 wt.% Ti alloys in 0.24 mol dm^?3 nitric acid solution at 38 °C has been employed to assist understanding of the roles of alloying elements in electrograining. The findings indicate that additions of magnesium and titanium to aluminium accelerate the corrosion of the substrate under the alkalization caused by the cathodic reactions. The accelerated dissolution and the consequent formation of hydrated alumina result in a decreased net cathodic current density in potentiostatic and potentiodynamic polarization conditions relative to the behaviour of aluminium. Copyright © 2014 John Wiley & Sons, Ltd.     

Effect of anodizing conditions on the cell morphology of anodic films on AA2024-T3 alloy

The effects of applied current density, anodizing time, and electrolyte temperature on the cell and pore morphology of anodic films and the voltage-time response obtained during galvanostatic anodizing of AA2024-T3 alloy in sulphuric acid electrolytes have been studied. Scanning electron microscopy was employed to observe the film morphology. Sponge-like porous structure was promoted by anodizing at relatively low current density and high electrolyte temperature. In contrast, linear porous structure was favoured under the converse conditions. Intermediate conditions resulted in films containing either sequential layers of the 2 morphologies or a morphology incorporating features of the 2 types; such conditions were associated with anodizing voltages in the range 25 to 35 V. The reasons for the morphological differences are proposed to be due to interactions between film growth stresses and stresses arising from oxygen evolution on the development of the alumina cells.     

Synthesis of malachite nanoparticles and their evolution during transmission electron microscopy

Malachite nanoparticles have been synthesized utilising the polyol-mediated synthesis. Reaction of copper sulphate with sodium carbonate in ethylene glycol medium results in the formation of malachite nanoparticles of sub-10 nm dimensions. The structure of malachite in the synthesized product was confirmed by X-ray diffraction and FTIR spectroscopy. Examination by high-resolution transmission electron microscopy revealed that nanoparticles are thermally decomposed to Cu(2)O and copper during exposure to the electron beam.     

Optimisation of the plasma electrolytic oxidation process efficiency on aluminium

Plasma electrolytic oxidation (PEO) is a surface treatment technology enabling fabrication of adherent thick (50–150 µm) coatings on light metal alloys with significantly enhanced hardness, wear and corrosion resistance compared with other conventional treatments. The technology has the potential to play a significant role in the transport sector for replacement of steel with light‐weight materials of improved durability. A main limitation of PEO lies in its relatively high cost, associated with high energy consumption and low coating efficiency. The present work explores possible routes to improve the process efficiency. It is shown that a combination of conventional pre‐anodising with sequential PEO treatment reduces specific energy consumption up to five times because of an increase of the coating growth rate, up to 10 µm/min, compared with existing PEO processes. A further approach to improved coating efficiency involves PEO in electrolytes with suspended fine or nanoparticles, which results in the formation of thicker coatings in reduced time as a result of the incorporation of the particles from the electrolyte into the coating. Additionally, melting of the coating material during the micro‐arc discharge process leads to formation of stabilised high‐temperature phases, such as tetragonal and cubic zirconia, which provide significantly improved microhardness of the coating material and give a potential for thermal barrier applications. Copyright © 2009 John Wiley & Sons, Ltd.     

Differentiation of 18O‐ and 16O‐rich layers in anodic alumina films by glow discharge time‐of‐flight mass spectroscopy

The performance of glow discharge time‐of‐flight mass spectrometry in isotopic differentiation is revealed using the distribution of oxygen isotopes ¹⁶O and ¹⁸O in barrier‐type anodic alumina films as a focus. Anodic alumina films comprising ¹⁸O‐rich layers of controlled thickness were formed by the appropriate combination of anodising of superpure aluminium in electrolytes enriched with ¹⁸O isotopes and of natural abundance of ¹⁸O isotopes. Analysis of the elemental depth profiles of selected ionic species, i.e. ¹⁶O¹⁸O, allowed determination of the locations of the ¹⁸O‐rich layers and the ¹⁸O/¹⁶O interface. Copyright © 2010 John Wiley & Sons, Ltd.     

Crack‐free sol‐gel coatings for protection of AA1050 aluminium alloy

Organically modified sol‐gel coatings have been investigated as potential replacements for chromate conversion treatments of an AA1050 aluminium alloy. The coatings were prepared by combination of a completely hydrolysable precursor of tetra‐n‐propoxyzirconium (TPOZ), with a partially hydrolysable precursor of glycidoxypropyltrimethoxysilane (GPTMS). GPTMS contains an organic functional group, which is retained in the sol‐gel coatings after the hydrolysis–condensation process. Different GPTMS/TPOZ ratios and withdrawal speeds were studied. Coatings produced using a low GPTMS/TPOZ ratio and a high withdrawal speed generated significant cracks due to the shrinkage of the coatings, with no corrosion protection of the alloy. It was found that increase of organic moieties reduced the shrinkage of the coatings and the tendency for crack formation. By control of process parameters and ratios of organic and inorganic moieties, crack‐free sol‐gel coatings above 1 µm thick, with improved corrosion protection, can be produced on the alloy surface. Copyright © 2010 John Wiley & Sons, Ltd.