Inorganic–organic sol gel hybrid coatings for corrosion protection of metals

Inorganic–organic hybrid coatings by sol–gel process are very suitable for fighting corrosion. Inorganic sols in hybrid coatings not only increase adhesion by forming chemical bonds between metals and hybrid coatings, but also improve comprehensive performances of polymer in the coatings. Different organic polymers or organic functionalities are introduced into gel network to achieve tailored properties, such as hydrophobic properties, increasing cross-linking density, etc. As for corrosion protection of metals organic components of hybrid coatings are selected to repel water and form dense thick films and reduce coating porosity. The factors, such as the ratio of inorganic and organic components, cure temperature, pigments in hybrid coatings, need to be optimized for attaining hybrid films with the maximum corrosion resistance. Electro-deposition technique offers relatively thick homogeneous defect-free hybrid coatings in comparison to dip or spin coating techniques. Green cerium ions and non-ionizable organic inhibitors are more developed in hybrid coatings nowadays than other corrosion inhibitors. Long-term corrosion resistance techniques of inhibitors are discussed. The inhibitors entrapped in the nanocontainers are doped in hybrid films to prolong release of the inhibitors to damaged zones, which is discussed in detail. Among all the nanocontainers of corrosion inhibitors the prospective techniques which show superior corrosion protection are cyclodextrin/organic inhibitor inclusion complexes and layer by layer assembly of organic corrosion inhibitors in nanocontainers. Super-hydrophobic property of hybrid coatings derives from low surface tension and surface roughness of hybrid coatings, which endues the films with excellent corrosion protection for metals, but the durable property of super-hydrophobic coatings needs to be improved for industrial application. An ideal multiple model of hybrid coatings for superior anti-corrosion of metals proposed is a combination of super-hydrophobic hybrid coatings and underlying hybrid coatings doped with sustained release of corrosion inhibitors on metal substrates.     

Influence of organic corrosion inhibitors on the corrosion performance of organic–inorganic hybrid coatings applied on aluminium alloy

The proposed work aims to develop and study sol–gel derived anticorrosion films for aluminium. To further improve performance of these films, organic corrosion inhibitors were incorporated into the films. The organic–inorganic hybrid films with and without corrosion inhibitors were deposited on an aluminium substrate by dip coating. The films were characterized by electrochemical impedance spectroscopy (EIS), DC polarisation techniques, and neutral salt spray test to evaluate their anticorrosion properties. This study shows that very low and very high MBT concentrations deteriorate the corrosion performance of coatings, and consequently, there is an optimum concentration of MBT. EIS results revealed a higher corrosion inhibitive activity of 2-mercaptobenzothiazole (MBT) compared to that of 2-amino-5-methylthiazole and 1,2,3 benzotriazole.     

Sol-Gel Coatings on Non-Oxide Planar Substrates and Fibers: A Protection Barrier Against Oxidation and Corrosion

Sol-gel coatings on non-oxide substrates can be used to prevent high temperature degradation and to improve wet corrosion resistance. Alumina coatings were investigated. The starting precursor was aluminium sec-butoxide, modified with chelating ligands such as 2,4-pentanedione or acrylic acid to prevent its precipitation in the presence of water. Stainless steel plates and Hi-Nicalon SiC fibers are often utilized in different kinds of applications and thus were selected as substrates. Thin films were deposited from the modified alkoxide solutions using dip-coating techniques. The parameters governing the process such as the aging of the sols, the viscosity, the withdrawal rate and the thermal treatment were investigated. The films were characterized (morphology, thickness) and showed an interesting behaviour as protection barrier in an aggressive medium.     

Sol–gel derived hybrid coatings as an environment friendly surface treatment for corrosion protection of metals and their alloys

Sol?Cgel derived organic inorganic hybrid coatings are effective corrosion protective systems for metals. They offer an excellent adhesion to metal as well as to the subsequent coat via strong covalent bond and a three dimensional network of ?CSi?CO?CSi?C linkages which helps to retard the penetration of corrosive medium through the coating. Unlike conventional surface protection methodology, silane based pre-treatment is an environment friendly technology with number of advantages like room temperature synthesis, chemical inertness, high oxidation and abrasion resistance, excellent thermal stability, very low health hazard etc. Further, the hybrid silane provides required flexibility and an increased compatibility with the subsequent coating in multicoat systems. The performance properties of hybrid systems depend on number of parameters like type of silane (mono or bis), degree of hydrolysis, type and dosage of inhibitive/barrier pigments (in case of pigmented system), application techniques, curing temperature and curing schedule, need to be optimized. A guideline formulation for maximum corrosion resistance with low environmental impact consist of a superprimer (a bis-silane with conventional resins, chrome free inhibitive pigments and additives) followed by epoxy or polyurethane top coat as per the exposure conditions.     

Active corrosion protection of various aluminium alloys by lithium-leaching coatings

This study presents the active protective properties of lithium-leaching coatings for a range of aluminium alloys. Coatings with and without lithium carbonate as leachable inhibitor were applied on the aluminium alloys, artificially damaged and exposed to the neutral salt spray. A combined approach of scanning electron microscopy and electrochemical measurements revealed that the lithium carbonate leaching coating provided effective corrosion inhibition on AA2024, AA7075, AA5083, and AA6014 by the formation of a protective layer in the defect area and preventing local corrosion processes despite the different intrinsic electrochemical activity of the alloys.     

Electrochemical study of the corrosion inhibition ability of “smart” coatings applied on AA2024

Smart epoxy coatings modified with different additives were applied on AA2024. The following three different systems were studied: a reference consisting of an epoxy coating containing chromate active pigments and two “smart” coatings modified with containers loaded with corrosion inhibitor—layered double hydroxides filled with mercaptobenzothiazole and tubular halloysites (HS) filled with 8-hydroxyquinoline. The thickness of the coatings was determined by scanning electron microscopy. The barrier properties and the average corrosion resistance were assessed by electrochemical impedance spectroscopy (EIS). The long-term corrosion repair ability of the various coatings was confirmed by EIS measurements carried for a period of 3 weeks in scratched samples. The ability of the smart additives to inhibit corrosion over defects with different sizes and geometry was studied at the microscale by using localized impedance spectroscopy (LEIS) and the scanning vibrating electrode technique. The results demonstrate that the additives provide effective corrosion inhibition on defects of various sizes. Moreover, the LEIS measurements give some important highlights concerning the mechanisms and kinetics of inhibition of each system.     

Electrochemical corrosion behavior of nanocrystalline zinc coatings in 3.5% NaCl solutions

The corrosion behavior of electrodeposited nanocrystalline (NC) zinc coatings with an average grain size of 43 nm was investigated in 3.5% NaCl solutions in comparison with conventional polycrystalline (PC) zinc coatings by using electrochemical measurement and surface analysis techniques. Both polarization curve and electrochemical impedance spectroscopy (EIS) results indicate that NC and PC coatings are in active state at the corrosion potentials, and NC coatings have much higher corrosion resistance than PC ones. The corrosion products on both coating surfaces are mainly composed of ZnO and Zn₅(OH)₈Cl₂·H₂O, but the corrosion products can form a relatively more protective layer on NC coating surfaces than on PC coatings. The EIS characteristics and corrosion processes of PC and NC zinc coatings during 330 h of immersion were discussed in detail.     

Novel use of glow discharge optical emission spectroscopy (GDOES) to study corrosion of AA2024‐T3 in the presence and absence of inhibitors

Elemental depth profiling by glow discharge optical emission spectroscopy has been used to characterise the corrosion products on AA2024‐T3. In previous work, the aluminium, oxygen and copper depth profiles were shown to provide information regarding surface roughening, the thickness of corroded layers and extent of copper de‐alloying/relocation. In the present work, the study is extended to the detection of corrosion inhibitors deposited on the exposed alloy surface in a model defect. The work includes a comparison of hybrid coatings doped with inhibitors encapsulated in nanocontainers and with the direct addition of inhibitor species to the coating matrix. The work also investigates the effects of inhibitor addition to sol–gel coatings or primer systems or both, highlighting the possible synergistic effects of mixed inhibitor systems. Copyright © 2015 John Wiley & Sons, Ltd.     

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.     

On the application of electrochemical impedance spectroscopy to study the self-healing properties of protective coatings

Active corrosion protection based on self-healing of defects in coatings is a vital issue for development of new advanced corrosion protection systems. However, there is a significant lack of experimental protocols, which can be routinely used to reveal the self-healing ability and to study the active corrosion protection properties of organic and hybrid coatings.The present work demonstrates the possibility to use EIS (electrochemical impedance spectroscopy) for investigation of the self-healing properties of protective coatings applied on a metal surface. The model EIS experiments supported by SVET (scanning vibrating electrode technique) measurements show that an increase of low frequency impedance during immersion in the corrosive medium is related to the suppression of active corrosion processes and healing of the corroded areas. Thus, EIS can effectively be employed as a routine method to study the self-repair properties of different protective systems. The 2024 aluminium alloy coated with hybrid sol–gel film was used as a model system to study the healing of artificial defects by an organic inhibitor (8-hydroxyquinoline).     

Benzaldehyde, 2-hydroxybenzoyl hydrazone derivatives as inhibitors of the corrosion of aluminium in hydrochloric acid

The effect of benzaldehyde, 2-hydroxybenzoyl hydrazone derivatives on the corrosion of aluminium in hydrochloric acid has been investigated using thermometric and polarization techniques. The inhibitive efficiency ranking of these compounds from both techniques was found to be: 2>3>1>4. The inhibitors acted as mixed-type inhibitors but the cathode is more polarized. The relative inhibitive efficiency of these compounds has been explained on the basis of structure of the inhibitors and their mode of interaction at the surface. Results show that these additives are adsorbed on an aluminium surface according to the Langmuir isotherm. Polarization measurements indicated that the rate of corrosion of aluminium rapidly increases with temperature over the range 30-55 degrees C both in the absence and in the presence of inhibitors. Some thermodynamic data of the adsorption process are calculated and discussed.     

Enhancing corrosion resistance of zinc-filled protective coatings using conductive polymers

Organic coatings containing zinc are amply used for the protection of metals, particularly steel structures. Ways to reduce the zinc content in the coating materials are sought for environmental and financial reasons. Our previous work (Kohl, Prog Org Coat 77:512–517, 2014; Kohl and Kalendová, Mater Sci Forum 818: 171–174, 2015a) suggested that one of the options consists in the use of conductive polymers in the formulation of the zinc coatings. The benefits of conductive polymers include nontoxicity, high stability, electric conductivity and redox potential. Previously we focussed on the effect of conductive polymers added to the organic coatings so as to complete the zinc volume concentration to 67%. The anticorrosion efficiency of the organic coatings was found to improve with increasing polyaniline phosphate or polypyrrole concentrations. Zinc content reduction in the system, however, did not attain more than 5%. The present work focusses on systems where the organic coatings are prepared with zinc having a pigment volume concentration PVC = 50%. Zinc content reduction in the system attains up to 20%. This work examines the mechanical and anticorrosion properties of the organic coatings with reduced zinc contents. The present work was devoted to the feasibility of using of conductive polymers in the formulation of coatings with reduced zinc contents. The conductive polymers included polyaniline, polypyrrole and poly(phenylenediamine); these were synthesised and characterised using physico-chemical methods. Polyphenylenediamine as a potential corrosion inhibitor has not been paid adequate attention so far. Subsequently, organic coatings with reduced zinc contents and containing the pigments at 0.5, 1 and 3% volume concentrations were formulated. The coatings were subjected to mechanical tests and accelerated corrosion tests to assess their mechanical and corrosion resistance. The corrosion resistance of the organic coatings was also studied by linear polarisation. The results of the mechanical tests, accelerated corrosion tests and linear polarisation measurements indicate that the organic coating properties get affected by the conductive polymer type as well as by the pigment volume concentration. The important finding is that the use of conductive polymers in coatings with reduced zinc contents was beneficial in all cases.     

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.     

碳钢低压冷喷涂铝涂层的海水耐蚀性

本文以Al和10%体积比Al2O3的混合粉末为原料,使用便携式低压冷喷涂设备,在Q235碳钢基体上喷涂了Al涂层. 测试涂层自腐蚀电位及动电位极化曲线,结合扫描电镜观察涂层表面及截面微观形貌,研究了低压冷喷涂Al涂层在海水中电化学腐蚀行为,并与高压冷喷涂和热喷涂铝涂层的耐蚀性比较. 结果表明,低压冷喷涂铝涂层结构较为致密,其耐蚀性比高压冷喷涂铝涂层的略低,而明显优于热喷涂铝涂层.     

Characterization of Paint by Fourier-Transform Infrared Spectroscopy,Raman Microscopy,and Scanning Electron Microscopy-Energy Dispersive X-ray Spectroscopy

The identification of automotive coatings has become important for forensic scientists to trace suspects. Popular automotive coatings include acrylic, amino, alkyd, nitro, and polyurethane paints. Various pigments and additives are added to the coatings, which may create difficulty in characterization of paint evidence. In this study, Fourier-transform infrared spectroscopy, Raman spectroscopy and scanning electron microscopy-energy dispersive X-ray spectroscopy were used to characterize an eleven-layer paint sample. Most layers were only a few micrometers thick. Infrared spectroscopy has several advantages in identifying resins and additives, while Raman is more effective in characterizing additives and inorganic pigments. Scanning electron microscopy-energy dispersive X-ray spectroscopy provides elemental analysis information. The results reveal that the combination of these techniques provides more accurate paint identification than using them separately.     

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.     

有机涂层在浸泡和干湿循环条件下劣化过程的EIS对比研究

应用电化学阻抗谱(EIS)技术以对比法研究了浸泡在3.5%NaCl溶液中的铁基有机涂层在浸泡和干湿循环条件下的劣化过程.干湿循环实验步骤为12h浸泡和12h干燥(298 K、50%RH).结果表明,根据EIS响应特征,浸泡和干湿循环下的涂层劣化过程均可分为3个主要阶段:涂层渗水阶段,基底金属腐蚀发生阶段和基底金属腐蚀发展与涂层失效阶段.与单一浸泡过程相比,干湿循环明显加速了腐蚀反应的发生,但减缓了其渗水、腐蚀发展以及涂层失效劣化过程.根据实验结果,深入讨论了干湿循环加速涂层劣化和涂层下基底金属的腐蚀机理.     

Efficiency of anticorrosive pigments based on modified phosphates

The paper deals with the study of modified phosphate compounds from their anticorrosion action point of view. The pigments start with zinc orthophosphate, the modification of which can give phosphosilicates, phosphomolybdates, or basic phosphates. In the region of cations the combination of zinc with calcium, strontium, barium, or aluminum are possible. The modified anticorrosive pigments differ in water solubility, inhibition efficiency of the aqueous extracts and anticorrosion actions in organic coatings. The various types of modified phosphates were studied. The effect of organic inhibitor in presence of anticorrosive inorganic pigments in coatings was determined.     

CHARACTERIZATION OF NANOSTRUCTURES:TOOLS AND CHALLENGES

Apart from long-known and applied nanostructures like carbon black for tyres or pigments for coatings nanotechnology has created highly sophisticated structures used for nano/molecular electronics,diagnostics,drug delivery, UV-absorbers etc.Often the main question to be solved analytically is the local determination of tiny amounts of chemicals resulting in an ever increasing need for highly sensitive as well as locally resolved techniques.Applications of techniques like mass spectroscopy,transmission el...     

Synthesize,Characterization, and Corrosion Inhibition of Polypyrrole Thin Films on Copper

Polypyrrole (PPy) coatings were synthesized on copper by electrochemical polymerization of pyrrole monomer in aqueous acidic and basic solutions by cyclic voltammetry. The coatings were characterized with CV, UV-visible absorption spectroscopy, Fourier transform infrared (FT-IR) spectroscopy, and scanning electron microscopy (SEM) techniques. The corrosion protection aspects of PPy coatings have been investigated using the potentiodynamic polarization technique and electrochemical impedance spectroscopy (EIS). The potentiodynamic polarization measurements show that the PPy coating has ability to protect the copper against corrosion. It was concluded that a complete corrosion protective PPy film could not be obtained through direct electro-oxidation procedure. This may be due to copper dissolution in the monomer oxidation potential range.