Synthesis and characterization of corrosion protective poly(2,5-dimethylaniline) coatings on copper

Poly(2,5-dimethylaniline) coatings were synthesized on copper (Cu) by electrochemical polymerization of 2,5-dimethylaniline in aqueous salicylate solution by using cyclic voltammetry. The characterization of these coatings was carried out by cyclic voltammetry, UV–visible absorption spectroscopy, Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM). The results of these characterizations indicate that the aqueous salicylate solution is a suitable medium for the electrochemical polymerization of 2,5-dimethylaniline to generate strongly adherent and smooth poly(2,5-dimethylaniline) coatings on Cu substrates. The performance of poly(2,5-dimethylaniline) as protective coating against corrosion of Cu in aqueous 3% NaCl was assessed by the potentiodynamic polarization technique. The results of the potentiodynamic polarization demonstrate that the poly(2,5-dimethylaniline) coating has ability to protect the Cu against corrosion. The corrosion potential was about 0.078 V versus SCE more positive in aqueous 3% NaCl for the poly(2,5-dimethylaniline) coated Cu than that of uncoated Cu and reduces the corrosion rate of Cu almost by a factor of 31.     

Electrodeposition of polyaniline, poly(2-iodoaniline), and poly(aniline-co-2-iodoaniline) on steel surfaces and corrosion protection of steel

Polyaniline (PANi), poly(2-iodoaniline) (PIANi), and poly(aniline-co-2-iodoaniline) (co-PIANi) were synthesized using cyclic voltammetry in acetonitrile solution containing tetrabuthylammonium perchlorate (TBAP) and perchloric acid (HClO₄) on 304-stainless steel electrodes. Adherent and black polymer films were obtained on the electrodes. The structure and properties of these polymer films were characterized by FTIR and UV-vis spectroscopy and electrochemical method. The corrosion performance of PANi, PIANi, and co-PIANi coated electrodes were investigated in 0.5 M hydrochloric acid (HCl) solutions by potentiodynamic polarization technique, open circuit potential-time curves and electrochemical impedance spectroscopy, EIS. It was found that the PANi film could provide much better protection than PIANi, and co-PIANi and PANi films have barrier property as well as acting as passivator. On the other hand PIANi and co-PIANi films are acting as barrier coatings which were related with the prevention of cathodic reaction taking place at metal\electrolyte interface. EIS measurement shows that every coating gives protection efficiency of greater than 75% after 48 h of immersion time in corrosive test solution.     

Anti-corrosive properties of polyaniline,poly(2-toluidine), and poly(aniline-co-2-toluidine) coatings on stainless steel

This study examines the use of polyaniline (PANi), poly(2-toluidine) (PT), and poly(aniline-co-2-toluidine) (co-PT) for corrosion protection of 304-stainless steel (SS) in 0.5 M HCl solution. The PANi, PT, and co-PT coatings were synthesized on SS substrates under cyclic voltammetric (CV) conditions from acetonitrile solution using tetrabuthylammonium perchlorate (TBAP) as supporting electrolyte and perchloric acid (HClO₄) as acid. These coatings were characterized by CV, FTIR, and UV–vis spectroscopy. The ability of PANi, PT, and co-PT to serve as corrosion protective coatings for SS was examined by open circuit potential-time (E_ocp-time), potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS) measurements. The results of this study reveal that PANi, PT, and co-PT acts as corrosion protective coatings on SS and every coating gives protection efficiency of greater than 80% after 48 h of immersion in corrosive test solution.     

Molybdate and molybdate/permanganate conversion coatings on Mg-8.5Li alloy

A novel environment-friendly conversion coating for Mg-8.5Li alloy was obtained by immersing in a solution of molybdate. The concentration of ammonium molybdate and the addition of potassium permanganate were discussed in this experiment. The surface morphology of the conversion coatings was observed by scanning electron microscopy (SEM), and the chemical composition was investigated by X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD). The corrosion resistance of Mg-8.5Li alloy and conversion coatings were investigated by means of potentiodynamic polarization, electrochemical impedance spectroscopy (EIS) and weight loss measurement. The results showed that the coatings with cracked morphology were homogeneous and uniform. The conversion coatings were mainly composed of metal-oxide as detected by XPS. The results of electrochemical measurement and weight loss measurement revealed that the molybdate conversion coating had better corrosion resistance than bare alloy and chromate conversion coating, and the molybdate/permanganate conversion coating had lower corrosion current density and higher coating resistance than the molybdate conversion coating.     

Electrodeposition of high corrosion resistance Cu/Ni-P coating on AZ91D magnesium alloy

High corrosion resistance Cu/Ni-P coatings were electrodeposited on AZ91D magnesium alloy via suitable pretreatments, such as one-step acid pickling-activation, once zinc immersion and environment-friendly electroplated copper as the protective under-layer, which made Ni-P deposit on AZ91D Mg alloy in acid plating baths successfully. The pH value and current density for Ni-P electrodeposition were optimized to obtain high corrosion resistance. With increasing the phosphorous content of the Ni-P coatings, the deposits were found to gradually transform to amorphous structure and the corrosion resistance increased synchronously. The anticorrosion ability of AZ91D Mg alloy was greatly improved by the amorphous Ni-P deposits, which was investigated by potentiodynamic polarization curve and electrochemical impedance spectroscopy (EIS). The corrosion current density (I_corr) of the coated Mg alloy substrate is about two orders of magnitude less than that of the uncoated.     

The corrosion behaviour of polypyrrole coating synthesized in phenylphosphonic acid solution

Electrochemical synthesis of polypyrrole (PPy) film was achieved on mild steel (MS), in monomer containing 0.1 M phenylphosphonic acid solution. The synthesis was carried out using cyclic voltammetry technique. It was found that the electrode surface could only become completely passive, after a few successive cycles in solution of 0.1 M pyrrole + 0.1 M phenylphosphonic acid. Then, the thickness of polymer film was increased with help of successive cycles in a relatively narrower potential range. The corrosion performance of polymer coating was investigated in 3.5% NaCl solution, using electrochemical impedance spectroscopy (EIS) and anodic polarization curves. It was shown that the coating had high stability and low permeability, under such aggressive conditions. The EIS results also showed that the coating exhibited important anodic protection behaviour on mild steel. The percent protection efficiency value (E%) was found to be 98.4% and the percent total porosity value (P%) was determined to be 0.752%, after 96 h exposure time to corrosive solution.     

The effect of carbon nanotubes on the corrosion and tribological behavior of electroless Ni-P-CNT composite coating

In this study, Ni-P-CNT composite coating was successfully deposited on the surface of copper by electroless plating. X-ray diffraction (XRD) analysis and scanning electron microscopy (SEM) were used to characterize the coatings. The wear behavior of the coatings was investigated using a pin-on-disk test rig and subsequently friction coefficient data were reported. The corrosion behavior of the Ni-P and Ni-P-CNT coated specimen were evaluated through polarization curves and electrochemical impedance spectroscopy (EIS) in 3.5 wt.% NaCl aqueous solution at the room temperature. The results indicated that the incorporation of carbon nanotubes (CNTs) in the coating improved both tribological behavior and corrosion resistance. These improvements have been attributed to superior mechanical properties, unique topological structure and high chemical stability of nanotubes.     

The optimization of microbial influenced corrosion resistance of HVOF sprayed nanostructured WC-10Co-4Cr coatings by ultrasound-assisted sealing

In this study, high-velocity oxygen-fuel (HVOF) sprayed nanostructured WC-10Co-4Cr coatings were subjected to seawater with sulfate-reducing bacteria (SRB) for different time. The effect of ultrasound-assisted sealing with aluminum phosphate on the microstructural features and microbial influenced corrosion (MIC) behavior was evaluated using scanning electron microscopy (SEM), potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The results showed that the ultrasound-assisted sealing promoted the infiltration of the sealant into as-sprayed coating, enhanced the resistance values of about one order of magnitude, and reduced the corrosion current density. During the whole immersion period, the MIC process of both unsealed and sealed coatings can be divided into two different stages, and the ultrasound-assisted sealing treatment significantly delayed the MIC process, suggesting that the ultrasound-assisted sealing with aluminum phosphate is an effective way for controlling the MIC of SRB on the WC-10Co-4Cr cermet coatings in marine environment.     

EIS diagnosis on the corrosion behavior of TiN coated NiTi surgical alloy

In this work titanium nitride (TiN) coatings were deposited on NiTi surgical alloy by arc ion plating (AIP). The open circuit testing and electrochemical impedance spectroscopy (EIS) have been employed to study the corrosion performance of the TiN coated samples in Troyde’s simulated body fluid. It was found that the TiN coating showed a good corrosion resistance at the beginning of long-term immersion; with the increase of immersion time, however, the corrosion resistance of the coating deteriorated after nearly 24 h of immersion; moreover, the large areas of the coating had fallen off the substrate after 30 days of immersion.     

Electrochemical synthesis of polythiophene on nickel coated mild steel and corrosion performance

Electrochemical polymerization of polythiophene (PTh) was investigated on nickel coated mild steel (MS) electrode, in LiClO₄ containing acetonitrile medium (ACN-LiClO₄). Nickel layer (1 μm thick) was deposited galvanostatically, from a proper bath solution. Then, the synthesis of PTh film was achieved in 0.1 M thiophene containing ACN-LiClO₄, by using cyclic voltammetry technique. The corrosion performances of nickel coated samples with and without polymer top coats were investigated in 3.5% NaCl solution, by using electrochemical impedance spectroscopy (EIS) and anodic polarization curves. The nickel coating behaved like a physical barrier and provided some protection to MS against corrosion. But its barrier property diminished significantly with time and failed to protect MS. It was shown that PTh top coat improved the barrier efficiency remarkably, and excellent protection efficiency was obtained against MS corrosion, for considerable exposure time in such aggressive environment.     

Corrosion properties of aluminium coatings deposited on sintered NdFeB by ion-beam-assisted deposition

Pure Al coatings were deposited by direct current (DC) magnetron sputtering to protect sintered NdFeB magnets. The effects of Ar⁺ ion-beam-assisted deposition (IBAD) on the structure and the corrosion behaviour of Al coatings were investigated. The Al coating prepared by DC magnetron sputtering with IBAD (IBAD-Al-coating) had fewer voids than the coating without IBAD (Al-coating). The corrosion behaviour of the Al-coated NdFeB specimens was investigated by potentiodynamic polarisation, a neutral salt spray (NSS) test, and electrochemical impedance spectroscopy (EIS). The pitting corrosion of the Al coatings always began at the voids of the grain boundaries. Bombardment by the Ar⁺ ion-beams effectively improved the corrosion resistance of the IBAD-Al-coating.     

The effect of heat treatment on the electrochemical corrosion behavior of reactive plasma-sprayed TiN coatings

The effect of heat treatment on the corrosion behavior of reactive plasma sprayed TiN coatings in simulated seawater was investigated by electrochemical methods such as the corrosion potential-time curve (E_corr − t), potentiodynamic polarization, electrochemical impedance spectroscopy (EIS) and SEM, etc. The results showed that the corrosion potential of TiN coatings increased after heat treatment; the corrosion current of the TiN coatings after heat treatment (be hereafter referred to as HT-TiN) was 13.3% of the untreated coatings (be hereafter referred to as UT-TiN), and the polarization resistance of HT-TiN was 20 times of UT-TiN, which indicated that the heat treatment had significantly increased the corrosion resistance of the coatings. The corrosion behavior of the coatings was mainly local corrosion, and the local corrosion behavior mainly took place at the microdefects (crack and pores) of the coatings. The porosity of the coatings was reduced after heat treatment. The reason was that TiN reacted with O₂ to form TiO₂ and Ti₃O during the heat treating, and volume expansion took place, which led to denser microstructure. The corrosion resistance of the coatings was therefore increased.     

Development of electroless Ni-Zn-P/nano-TiO2 composite coatings and their properties

Ni-Zn-P-TiO₂ composite coatings were successfully obtained on low carbon steel by electroless plating technique. Deposits were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy-dispersive analysis (EDS) studies. The hardness and microstructure of as plated and heat treated Ni-Zn-P and Ni-Zn-P-TiO₂ composite coatings were analyzed. The change in microstructure and higher hardness was noticed for heat treated composite. The corrosion resistance behavior of as plated and heat treated Ni-Zn-P and Ni-Zn-P-TiO₂ coatings was investigated by anodic polarization, Tafel plots and electrochemical impedance spectroscopic (EIS) studies in 3.5 wt% NaCl solution. The composite coating exhibited enhanced corrosion resistance property over Ni-Zn-P coating.     

A novel electrodeposited Cu-Zn-Bi film with increased corrosion resistance in a 0.05 M K2SO4 solution

A single phase Cu-Zn-Bi film is fabricated on the steel wire by electrodeposition. Bi addition (∼1 wt.%) greatly increases the corrosion resistance of brass (Cu−36 wt.% Zn) film in a 0.05 M K₂SO₄ solution as shown by potentiodynamic polarization and electrochemical impendence spectroscopy (EIS) experiments. It is proposed that the main reason for the improvement in the corrosion resistance by the Bi addition is that it greatly increased the crack resistance, which thus prevents crack-induced galvanic corrosion occurring between the brass film and the steel substrate.     

Study on the deterioration process of a chromium-free conversion coating on AZ91D magnesium alloy in NaCl solution

The morphology of a chromium-free conversion coating for AZ91D magnesium alloy was observed with an Atomic Force Microscopy. The results showed the uniform conversion coating has a relatively smooth appearance with shallow valleys. The EDX results indicated that the compositions of the coating were mainly compounds of Mg, Al, Mn, P, Ca and O. The XRD result showed that the coating contained amorphous materials and a small quantity of crystalline compound. The pitting product of the coating in NaCl water solution mainly composed of Mg, Cl, Mn, P, Ca and O. The corrosion behavior of the samples in NaCl solution was also studied by electrochemical impedance spectroscopy (EIS), which was characterized by one capacitive loop and one inductive loop. Based upon study on both a mathematical model for Faradic admittance of coating in NaCl solution and EIS, it could be considered that the inductive loop was caused by the adsorption of Cl anion and the appearance of pitting corrosion. A degradation mechanism of the coating in NaCl solution is set forth: dissolution velocity of the Cl⁻ adsorption regions of the coating is higher than those non-adsorption regions, for Cl⁻ anions are selective adsorption at some regions of coating surface. When the adsorption regions of coating layer are penetrated by dissolution, the pitting comes into being. The degradation mechanism of conversion coating and the mathematical model are consistent with the EIS results, polarization measurement results and coating's corrosion test results.     

Synthesis, characterization, and corrosion protection properties of poly(N-(methacryloyloxymethyl) benzotriazole-co-methyl methacrylate) on mild steel

The copolymers from different feed ratios of N-(methacryloyloxymethyl) benzotriazole (MMBT) and methyl methacrylate (MMA) has been synthesised using free radical solution polymerization technique and characterized using FT-IR and ¹³C NMR spectroscopy. The thermal stability of the polymers was studied using theremogravimetrtic analysis (TGA). The corrosion behaviors of mild steel specimens dip coated with different composition of copolymers have been evaluated by potentiodynamic polarization and electrochemical impedance spectroscopic (EIS) method. These electrochemical properties were observed in 0.1 M HCl medium. The polarization and impedance measurements showed different corrosion protection efficiency with change in composition of the copolymers. It was found that the corrosion protection properties are owing to the barrier effect of the polymer layer covered on the mild steel surfaces. However, it was observed that the copolymer obtained from 1:1 mole ratio of MMBT and MMA exhibited better protection efficiency than other combinations.     

2-Mercaptobenzothiazole doped chitosan/11-alkanethiolate acid composite coating: Dual function for copper protection

Chitosan (CS) hydrogel loaded with the well-known corrosion inhibitor 2-mercaptobenzothiazole (MBT) has been introduced into a composite coating to improve copper protection. This composite coating, which has both anticorrosion and antibacterial properties, was fabricated onto the surface of copper by combining a simple self-assembled monolayer technique with a sol-gel method. The anti-corrosion ability of the coating in 3.5 wt.% NaCl solution was investigated by electrochemical methods including potentiodynamic polarization and electrochemical impedance spectroscopy. The protection efficiency of the coating is 97.70%, calculated on the basis of the corrosion current density. The stability and integrity of the composite coating were evaluated by field emission scanning electron microscopy (FESEM) and energy dispersive spectrometry (EDS). The FESEM and EDS results suggest that the composite coating endows the copper substrate with antibacterial properties, as untreated bare copper underwent microbiologically influenced corrosion in the presence of sulphate reducing bacteria (SRB). This antibacterial feature was further confirmed by the SRB culture method. In a 3.5% NaCl solution and highly corrosive SRB culture media, the as-prepared CS based composite coating gave corrosion protection by exhibiting better barrier effects against the attack of aggressive environments.     

Effect of deformation on the electrochemical behavior of hot-dip galvanized steel sheets

The main purpose of employing pre-coated steel sheets is to minimize corrosion of steel. However, coatings can be severely affected by forming processes. In the forming processes, due to the different modes of deformation, the strain levels are different and so can affect the properties of the coatings to a varying degree. Special attention has to be paid to the influence of deformation conditions on the performance of the coating, as regards protection against corrosion. The adhesion of the coating must remain good, and the surface should not be damaged during forming. Therefore, it is necessary to study the behavior of its corrosion resistance against the deformation.In this work, effect of strain path on the corrosion behavior of hot-dip galvanized steel sheets has been studied. Corrosion behavior of hot-dip galvanized steel sheets at various strain levels has been evaluated under four different strain paths namely, biaxial, plane strain, uniaxial (drawing) and tensile modes. The sheets were deformed by a limiting dome height test (LDH) set-up. A correlation between the degree of deformation and the loss in extent of corrosion protection offered by the coating has been established by carrying out electrochemical studies such as potentiodynamic polarization and impedance spectroscopy (EIS) in 3.5% NaCl solution. The present study shows that increase in deformation increases the extent of delamination of the coating for all the modes of deformation. The severity of deformation on delamination, however, has been found to vary in the order of, tensile < uniaxial < plane < biaxial.     

Electrochemical adsorption properties and inhibition of copper corrosion in chloride solutions by ascorbic acid: experimental and theoretical investigation

In this study, the effect of ascorbic acid in the electrochemical behavior of copper has been investigated in 3.5 % NaCl solution using potentiodynamic polarization and electrochemical impedance spectroscopy. Current-potential curve and Nyquist diagrams were obtained in different concentrations of ascorbic acid. The surface morphology of copper after its exposure to 3.5 % NaCl solution with and without of ascorbic acid was examined by scanning electron microscopy. The obtained results show that ascorbic acid inhibits corrosion of copper in 3.5 % NaCl solution. The inhibition activity of ascorbic acid increases with a decrease in the concentration of ascorbic acid.     

Preparation of superhydrophobic films on titanium as effective corrosion barriers

Stable superhydrophobic films were prepared on the electrochemical oxidized titania/titanium substrate by a simple immersion technique into a methanol solution of hydrolyzed 1H,1H,2H,2H-perfluorooctyltriethoxysilane [CF₃(CF₂)₅(CH₂)₂Si(OCH₂CH₃)₃, PTES] for 1 h at room temperature followed by a short annealing at 140 °C in air for 1 h. The surface morphologies and chemical composition of the film were characterized by means of water contact angle (CA), field emission scanning electron microscopy (FESEM), atomic force microscope (AFM) and X-ray photoelectron spectroscopy (XPS). The water contact angle on the surface of this film was measured to be as high as 160°. SEM images showed that the resulting surfaces exhibited special hierarchical structure. The special hierarchical structure along with the low surface energy leads to the high surface superhydrophobicity. The corrosion resistance ability and durance property of the superhydrophobic film in 3.5 wt.% NaCl solution was evaluated by the electrochemical impedance spectroscopy (EIS). The anticorrosion properties of the superhydrophobic film are compared to those of unmodified pure titanium and titania/titanium substrates. The results showed that the superhydrophobic film provides an effective corrosion resistant coating for the titanium metal even with immersion periods up to 90 d in the 3.5 wt.% NaCl solution, pointing to promising future applications.