Modeling electrochemical surface responses for PANI bronze corrosion protection

Plackett–Burman experimental design was carried out in order to optimize the experimental conditions of polyaniline (PANI) electrodeposition for Cu10Sn bronze alloy corrosion protection in neutral aerated aqueous 0.5 M chloride medium. Seven factors including scan rate, aniline concentration, hydroxyl ions concentration, cycle number, nature of solvent, starting potential, and final potential for the cyclic voltammetry study were considered. The experimental responses were Ecorr, βa, βc, B, Jcorr, Rp, the percentage of protection efficiency and the coatings porosities. A linear mathematical model was applied to estimate the coefficients related to the different experimental responses. The significance of the different factors was evaluated through Pareto analysis. The optimum conditions for PANI electrodeposition were estimated and discussed. PANI coatings were concluded to offer protection efficiency higher than 90% for Cu10Sn bronze alloy. Copyright © 2016 John Wiley & Sons, Ltd.     

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.     

Ultrathin organic layers for corrosion protection

The adsorption and self-organisation process of alkyl-phosphonic acids and phosphoric acid monoalkyl esters on technical aluminium surfaces have been investigated by different surface sensible techniques: Grazing angle FT-IR- spectroscopy, angle dependent XPS and Auger- spectroscopy. The aim of these studies was to replace the present technical procedure for pretreatment of aluminum surfaces with Chromate acid in order to improve the corrosion inhibition and the coating adhesion. The ability for self-assembly is given by substances which have a surface reactive group and a long-aliphatic or aromatic spacer and a supramolecular order is built-up between these spacers. The results show that these molecules are able to adsorb spontaneously onto the aluminum surface and subsequently a structured molecular order is formed. These effects were confirmed by industrial linked adhesion and corrosion tests.     

Robust self-healing waterborne polyurethane coatings via dynamic covalent Diels-Alder bonds for corrosion protection

For waterborne polyurethanes (PUs), balancing robust mechanical performances and excellent self-healing ability is a great challenge. Here, we show that this goal can be achieved by a rational tuning of the PU chemistry. In particular, we synthesized an anionic self-healing waterborne PU using acetone process, in which 2,2-bis(hydroxymethyl)propionic acid (DMPA) serves as inner emulsifier, thermally dynamic Diels-Alder bonds act as healing motifs and hexamethylene diisocyanate trimer is the crosslinker. The mechanical performance can be tuned by increasing DMPA concentration due to the gradually increased hard segment contents and ionic interactions. The tensile stress and elongation at break of films containing 5.6 wt% of DMPA are 24.9 MPa and 911.9%, respectively. Moreover, dynamic reversible Diels-Alder bonds located in main chains and cross-linking points ensure excellent self-repairing capability. Upon mechanical damage, the tensile stress can be restored to 95% of its initial value. Electrochemical impedance spectroscopy also points out an outstanding barrier ability and excellent corrosion protection performance of the coatings, which can be recovered even after serious damages.     

Sol-gel ZrO2 coatings for chemical protection of stainless steel

ZrO₂ coatings deposited on 316 L stainless steel sheets were synthesized by sol-gel method using Zr(OC₃H₇)₄ as precursor and isopropanol, glacial acetic acid, and water as solvents for application with ultrasounds. Different solutions for dip-coating were prepared with compositions varying between 0.025 and 0.9 mol/dm³ of ZrO₂. X-ray diffraction shows that the films densified at 800°C are crystalline with a tetragonal structure. The thickness of the coatings varied from 0.35–0.75 m. The influence of the ZrO₂ coatings on the corrosion behavior of stainless steel substrates in aqueous NaCl was studied through potentiodynamic polarization curves at 1 mV/s. The values of the electrochemical parameters allow for an explanation of the role of the films in the increased resistance of steel against corrosion in moderately aggressive environments.     

Waxes for powder coatings

Since the first beginnings at the end of the 50^th, the powder coating technology has become a perfected alternative in product and procedure respect to liquid paints. Powder coatings are primarily a mixture of synthetic resins, pigments and additives offering economical and ecological advantages compared to other coating systems. The raw materials are mixed, extruded and ground to coating powders. Waxes play an important part as additives in powder coatings. Production, storage and processing as well as the properties of the applied powder coating can be influenced positively by different waxes. Various waxes and their advantages are demonstrated by practical advantages.     

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.     

New epoxy-siloxane hybrid binder for high performance coatings

The novel chemistry achieved by condensation reaction of an aliphatic epoxy with a polysiloxane results in an epoxy-siloxane hybrid binder whose unique physical characteristics allow its use as a durable binder for the protective coatings industry. The new epoxy-siloxane coating system enables the zinc primer to be protected by a single topcoat. This results in reductions in application time, less overspray and a much simplified maintenance for corrosion protection. Furthermore the reduced number of coats and overspray results in about 70% less solvent emission to the atmosphere.     

Surface treatment of zinc by Schiff’s bases and its corrosion study

The zinc metal surface is chemically modified by newly synthesized Schiff’s bases and its corrosion protection is investigated. The influence of concentration of Schiff’s bases on modification of zinc surface and immersion time in treatment bath are investigated and optimized for maximum corrosion protection efficiency. The electrochemical studies of treated zinc specimens are performed in aqueous acid solution using galvanostatic polarization technique. The treated zinc samples show good corrosion resistance. The recorded electrochemical data of chemically treated samples indicate a basic modification of the zinc surface. The protection efficiency of organic layer formed on zinc surface is tested by varying the acid concentration and temperature of the corrosive medium. The corrosion protection efficiency increases with the concentration of Schiff’s bases and immersion time. This is due to a strong interaction between zinc and the organic molecules, which results in the formation of a protective layer. This layer prevents the contact of aggressive medium with the zinc surface. The surface modification is confirmed by the scanning electron microscopy images. The interaction between metal atoms and Schiff’s bases is also established by IR studies. Published in Russian in Elektrokhimiya, 2007, Vol. 43, No. 7, pp. 886–892. The text was submitted by the authors in English.     

Synthesis and characterization of polyaniline nanoparticles in phosphonic acid amphiphile aqueous micellar solutions for waterborne corrosion protection coatings

Polyaniline (PANI) dispersions consisting of 270 to 380 nm sized particles were prepared by oxidation with ammonium peroxydisulfate (APS) in n‐decylphosphonic acid (DPA) micellar solutions. The green dispersions do not undergo macroscopic precipitation for more than a year. The synthesized DPA doped PANI exhibited enhanced electrical conductivity (3.6 S cm^?1 ) compared with DPA‐PANI (2.3 x 10 ^{? 4} S cm ^{? 1}) prepared by postsynthesis treatment of the PANI‐base with DPA. It was shown that through protonation with decylphosphonic acid, polyaniline showed a significantly enhanced solubility in common organic solvents like chloroform, xylene, etc. The synthesized PANI was characterized by intrinsic viscosity, solubility, FT‐IR , conductivity, SEM , and TGA measurements. The wide‐angle X ‐ray diffraction study revealed the appearance of a peak located at low angles (d = 29.4 – 35.3 Å) suggesting the formation of layered structure of PANI backbone separated by long alkyl side chains of DPA. The anticorrosive performance of the bilayer coatings composed of a bottom layer of DPA doped polyaniline covered with a polyvinyl butyral topcoat, have been demonstrated for steel exposed to neutral saline solutions. It was found that the inhibitive properties of DPA dopant provides further protection to the base metal through smart release when damage is produced on the surface of the coating. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 1606–1616     

Polyimide,polybenzimidazole-in situ-polyaniline nanoparticle and carbon nano-onion-based nanocomposite designed for corrosion protection

This effort reports on novel polyimide (PI) and polybenzimidazole (PBI)-based system for corrosion protection. Polyaniline nanoparticle was generated in situ in polybenzimidazole (PBI-in-PANI). Carbon nano-onion (CNO) was opted as nanofiller. Ultimately, hybrid system of polyimide/polybenzimidazole-in situ-polyaniline nanoparticle/carbon nano-onion (PI/PBI-in-PANI/CNO) was developed. Temperature dependency of molecular weight of PBI was checked using gel permeation chromatography. Field emission scanning electron microscopy revealed fine network like morphology for PI/PBI-in-PANI/CNO nanocomposite. Transmission electron microscopy depicted small spherical PBI-in-PANI nanoparticle and CNO in matrix. At 180°C, conductivity of PI/PBI-in-PANI and PI/PBI-in-PANI/CNO series was enhanced in range of 1.6–2.8 and 3.0–3.3?S?cm^?1. About 5% PI/PBI-in-PANI/CNO nanocomposite coating enhanced corrosion protection effect up to 70%.     

Surface activation influencing the microstructure of Zn(Ca) phosphate coatings

Zinc and zinc calcium phosphate coatings on steel were formed by dipping in commercial baths. A surface activation with titanium phosphate influences not only the film morphology but also the composition of the conversion films. Qualitative phase analysis of the polycrystalline deposits reveals a typical phosphophyllite crystal growth apart from hopeite and scholzite respectively. The growth rate depends on the free surface of the steel; the contact area to the solution controls the rate of iron pickling.     

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.     

Electropolymerized coatings of poly(o‐anisidine) and poly(o‐anisidine)‐TiO2 nanocomposite on aluminum alloy 3004 by using the galvanostatic method and their corrosion protection performance

Poly(o‐anisidine) (POA) and poly(o‐anisidine)‐TiO₂ (POA‐TiO₂) nanocomposite coatings on aluminum alloy 3004 (AA3004) have been investigated by using the galvanostatic method. The electrosynthesized coatings were characterized by FT ‐ IR spectroscopy, XRD, SEM ‐ EDX and SEM. The corrosion protection performance of POA and POA‐TiO₂ nanocomposite coatings was investigated in the 3.5% NaCl solution by using potentiodynamic polarization technique and electrochemical impedance spectroscopy. The results show that the corrosion rate of the nanocomposite coatings is about 900 times lower than the bare AA3004 under optimal conditions. Copyright © 2013 John Wiley & Sons, Ltd.     

Effects of Rice Straw Powder (RSP) Size and Pretreatment on Properties of FDM 3D-Printed RSP/Poly(lactic acid) Biocomposites

To develop a new kind of environment-friendly composite filament for fused deposition modeling (FDM) 3D printing, rice straw powder (RSP)/poly(lactic acid) (PLA) biocomposites were FDM-3D-printed, and the effects of the particle size and pretreatment of RSP on the properties of RSP/PLA biocomposites were investigated. The results indicated that the 120-mesh RSP/PLA biocomposites (named 120#RSP/PLA) showed better performance than RSP/PLA biocomposites prepared with other RSP sizes. Infrared results showed that pretreatment of RSP by different methods was successful, and scanning electron microscopy indicated that composites prepared after pretreatment exhibited good interfacial compatibility due to a preferable binding force between fiber and matrix. When RSP was synergistically pretreated by alkaline and ultrasound, the composite exhibited a high tensile strength, tensile modulus, flexural strength, and flexural modulus of 58.59, 568.68, 90.32, and 3218.12 MPa, respectively, reflecting an increase of 31.19%, 16.48%, 18.75%, and 25.27%, respectively, compared with unmodified 120#RSP/PLA. Pretreatment of RSP also improved the thermal stability and hydrophobic properties, while reducing the water absorption of 120#RSP/PLA. This work is believed to provide highlights of the development of cost-effective biocomposite filaments and improvement of the properties of FDM parts.     

Sol-gel coatings for chemical protection of stainless steel

Sol-gel thin coatings of ZrO₂, SiO₂, 70SiO₂-30TiO₂ and 88SiO₂-12Al₂O₃ compositions (mole %) have been prepared from sonocatalyzed sols and deposited by dip-coating technique on 316L stainless steel foils. The influence of the coatings on the chemical corrosion of the substrate has been measured through potentiodynamic polarization curves in aqueous 15% H₂SO₄ solution between 25 and 50°C. The values of the corrosion potential, polarization resistance and corrosion rate have been determined. Analysis of the data combined with scanning electron microscopy studies indicate that the films act as a geometric blocking against exposure to the corrosive media and increase the lifetime of the substrate up to a factor 8.5.     

Parameters controlling the evaluation of polymeric coatings for carbon steel alloy

The efficiency of polymeric coatings as corrosion protective materials for carbon steel alloy in sea water was evaluated by different methods: electrochemical techniques (open circuit and potentiodynamic measurements), analytical and spectroscopic techniques (inductive coupled plasma, scanning electron microscopy and X‐ray diffraction). The study was made using ethylene propylene diene monomer (EPDM)/poly&!lpar;ethylene&!rpar; (PE) blend of different ratios. The effect of blend ratio on corrosion protection efficiency was investigated. The best results for corrosion control were achieved using samples with 2 mm thickness. The data obtained reveal that applying adhesive on the substrate increases the protective properties of the coatings. Copyright © 2006 John Wiley & Sons, Ltd.     

Efficient and robust coatings using poly(2-methyl-2-oxazoline) and its copolymers for marine and bacterial fouling prevention

Molecular design, fabrication, and properties of thin-film coatings based on poly(2-methyl-2-oxazoline) (PMOX) and its copolymers were investigated to tackle problem of marine and bacterial fouling prevention. The ultraviolet crosslinkable macromonomer poly(2-methyl-2-oxazoline) dimethylacrylate was synthesized by cationic ring-opening polymerization in a microwave reactor initiated by 1,4-dibromobutane. In order to study the charge effect of the PMOX coatings on the adhesion of fouling organisms, PMOX surfaces with negative, neutral, and positive ζ-potential values were prepared by copolymerization with the positively charged monomer [2-(methacryloyloxy)-ethyl]trimethylammonium chloride. The coatings were stable in sea water for at least 1 month without significant reduction in the film thickness. The marine antifouling activity was evaluated against barnacle cyprids Amphibalanus amphitrite and algae Amphora coffeaeformis. Results showed that PMOX coatings provide effective reduction of the settlement regardless of the molar mass and surface charge of the polymer. Bacterial adhesion test showed that PMOX coatings effectively reduce Staphylococcus aureus and Escherichia coli adhesion. Owing to its good stability and antifouling activity PMOX has a great potential as antifouling coating for marine antifouling applications. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016, 54, 275–283     

An orthogonal protection strategy for the synthesis of 2-substituted piperazines

Tetrahydro-1H-oxazolo[3,4-a]pyrazin-3(5H)-ones are readily prepared from the bis-carbamate protected piperazine-2-carboxylic acids and serve as orthogonally protected piperazines from which a variety of 2-substituted piperazines can be prepared. Sodium benzylate and sodium phenoxides react at the C-5 carbon of the oxazolidinone to yield 2-(benzyloxymethyl)piperazines and 2-(phenoxymethyl)piperazines, respectively. The tetrahydro-1H-oxazolo[3,4-a]pyrazin-3(5H)-ones also provide convenient scaffolds from which 2-benzyl- and 2-phenethylpiperazines are prepared.     

Development of a read-across workflow for skin irritation and corrosion predictions

We developed a read-across workflow using the OECD QSAR Toolbox for the prediction of skin irritation and corrosion. In the workflow, we gathered analogues using an improved profiler for skin irritation and corrosion to define valid categories. In addition, we refined categories by removing chemicals based on melting points and structural features. Finally, prediction results were obtained using our self-determined rule for read-across. In this rule, we decided the number of analogues from which the read-across is performed, analogue selection criteria (i.e. high similarity vs. near log P_ow) and prediction rule (i.e. majority vs. unanimity). We created a program for the optimization of read-across workflows. We applied this program to 313 chemicals in the training set and sought the optimized workflows among >1000 possible choices of profilers and ways of subcategorization and data gap filling. Use of the optimized workflows provided highly accurate, unbiased, user-independent and reproducible read-across predictions. The prediction results obtained from read-across workflows can be used for the selection of in vitro test methods or as part of the weight-of-evidence approaches in the Integrated Approach on Testing and Assessment for skin irritation and corrosion. Moreover, these results can be used for screening purposes and/or preliminary hazard assessment.