Sol-Gel Deposition of ZrO2 Films in Air and in Oxygen-Free Atmospheres for Chemical Protection of 304 Stainless Steel: A Comparative Corrosion Study

ZrO₂ coatings for corrosion protection were deposited on 304 stainless steel by sol-gel method using zirconium propoxide as precursor and densified in air and in oxygen-free (argon or nitrogen) atmospheres. XRD and IR data of the films were practically independent of the atmosphere used in the densification step showing that the ceramic oxide is properly formed from the precursor. The corrosion behavior of the stainless steel substrate was studied by potentiodynamic polarization curves in the absence and the presence of ZrO₂ coatings prepared in air, argon or nitrogen. The coatings extended the lifetime of the material by a factor of almost eight in a very aggressive environment, independently of the preparation procedure. The possibility of depositing pure or mixed oxide films by sol-gel methods in the absence of additional oxygen will allow the preparation of specific coatings onto oxygen-reactive substrates.     

Achieving ultra-low friction of a-C:H film grown on 9Cr18Mo steel for industrial application via programmable high power pulse magnetron sputtering

Owing to the high hardness and hydrogen passivation of carbon bonds, hydrogenated diamond-like carbon (a-C:H) film has shown promising potential to achieve ultra-low friction and wear on steel surfaces. Here, a-C:H film was successfully deposited on 9Cr18Mo steel via programmable high power pulse magnetron sputtering and potential application for industrial was evaluated. The a-C:H films against different mating materials of GCr15 steel balls, Al₂O₃, Si₃N₄, ZrO₂, and a-C:H-coated GCr15 balls all showed ultra-low friction under a normal load of 5 N in a dry ambient air environment. Among them, self-mating tribo-system a-C:H films on steel surfaces and a-C:H-coated steel balls achieve best friction performance; the principal reason is that both contacting surfaces coated with a-C:H film have the lower electron affinities compared with other tribo-systems. However, the differences of coefficient of friction (COF) for uncoated-GCr15, Al₂O₃, ZrO₂, Si₃N₄, and a-C:H(GCr15) balls can be attributed to different sizes of clustering in wear debris. This work provides new insights on synthesis and industry application of the a-C:H films with ultra-low friction properties.     

Silica-Zirconia Sol–Gel Coatings Obtained by Different Synthesis Routes

Homogeneous xSiO₂-(1−x)ZrO₂ coatings have been prepared onto glass-slides, monocrystalline Si and stainless steel (AISI 304) using sols prepared via acid and basic catalysis. Zirconium tetrabutoxide (TBOZr), zirconium n-propoxide (TPZ), tetraethoxysilane (TEOS) and methyltriethoxysilane (MTES) were used as precursors of zirconia and silica, respectively. The different parameters involved in the synthesis procedure, as molar ratios H₂O/alkoxides, NaOH/alkoxides, and sintering temperature have been analysed, correlating the stability and rheological properties of the sols. The evolution and structure of the sols and coatings have been studied by FTIR. Coatings have been prepared by dipping from acid and basic sols. Electrophoretic Deposition (EPD) technique has also been used to prepare coatings onto stainless steel from basic particulate sols in order to increase the critical thickness. A maximum thickness of 0.5 μ m was reached by both dipping and EPD process for 75SiO₂: 25 ZrO₂ composition. The critical thickness decreases with ZrO₂ amount depending strongly of the drying conditions. Si–O–Zr bonds have been identified by FTIR, indicating the existence of mixed network Si–O–Zr in the coatings obtained by the different routes. Crystallisation of ZrO₂(t) was only observed at high sintering temperature (900^∘C) by FTIR and confirmed by DRX.     

Ormocer (ZrO2-PMMA) Films for Stainless Steel Corrosion Protection

The chemical protection of 316 L stainless steel coated with ORMOCER coatings of polymethylmethacrylate (PMMA) and ZrO₂ has been verified. The coatings were dip-coated on the substrates from sols prepared by mixing zirconium propoxide (ZrOC₃H₇)₄, isopropanol (C₃H₇OH), glacial acetic acid (CH₃COOH), polymethylmethacrylate and water under application of ultrasounds. The films were heat treated between 40 and 300°C in air up to 20 h. Their morphology was studied by electron scanning microscopy (SEM). Their anticorrosion behavior was analysed in 0.5M-H₂SO₄ solutions through potentiodynamic polarization curves at room temperature.The influence of the sol preparation, coating composition as well as of the duration and temperature of heat treatments on the corrosion parameters is reported. The films act as geometric blocking layers against the corrosive media and increase the lifetime of the substrate up to a factor 30.     

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.     

含O2高温高压CO2环境中3Cr钢腐蚀产物膜特征

采用高温高压反应釜分别开展3Cr钢在CO2和O2共存、单独CO2和单独O2三种气体条件下的腐蚀实验,利用X射线衍射仪(XRD)、扫描电子显微镜(SEM)、能量色散X射线能谱(EDS)和电化学方法研究了3Cr钢在高温高压含有O2的CO2环境中的腐蚀产物膜特征.结果表明,在含有O2的CO2的条件下,3Cr钢表面腐蚀产物膜疏松多孔,主要成分为FeCO3、Fe3O4和Fe2O3,腐蚀产物中未见明显Cr元素富集,3Cr钢表现出点蚀的腐蚀形态.3Cr钢在高温高压含O2的CO2腐蚀条件下内外膜层电阻(Rf1、Rf2)和电荷传递电阻Rt均比仅含有CO2腐蚀环境的低,双电层电容(Cdl)和内外膜层电容(Cf1、Cf2)均比仅含有CO2腐蚀环境的高.含有O2的CO2条件下,其保护性显著低于单一CO2条件下形成的腐蚀产物膜.提出了在含O2的CO2气体条件下,3Cr钢表面存在由多种物质组成的腐蚀产物,这导致腐蚀产物疏松多孔,不会形成单一CO2条件下存在的显著提高腐蚀产物膜保护性的Cr(OH)3层,从而促进了3Cr钢的析氢腐蚀和酸性介质中的吸氧腐蚀的机理.     

Silica-Zirconia Coatings Produced by Dipping and EPD from Colloidal Sol–Gel Suspensions

SiO₂-ZrO₂ sols have been prepared via acid catalysis using a commercial colloidal suspension of zirconia and two silica alkoxides; tetraethoxysilane (TEOS) and methyltriethoxysilane (MTES). Suspensions with 10, 15 and 25-mol% of ZrO₂ were prepared. The stability of the suspensions was followed by rheological measurements showing that the amount of water incorporated with the colloidal suspension is the factor that limits the maximum ZrO₂ content. Coatings have been prepared by dipping using the suspensions up to 25-mol% ZrO₂ onto glass-slides at different withdrawal rates. EPD process has been used to prepare coatings onto stainless steel AISI 304 using the suspension with 25-mol% ZrO₂ at different pHs. The parameters associated with the EPD process (current density, electric field, potential and deposition time) have been evaluated. The critical thickness for a ZrO₂ addition of 25-mol% was 0.8 μm and it increased for diminishing ZrO₂ content.     

Sol–gel derived porous zirconium dioxide coated on 316L SS for orthopedic applications

The zirconia ceramics offers the required biocompatibility and corrosion resistance in the physiological medium, making it applicable for biomaterials. But, adequate utilization of porous zirconium dioxide (ZrO₂) thin film has not been assessed. Hence, in the present work an attempt has been made to utilize the corrosion resistance and biocompatibility property of porous ZrO₂. The ZrO₂ were prepared using the sol–gel process and coated on 316L SS substrate via dip-coating technique. The phase composition, morphology and the elemental distribution of the coatings were investigated using X-ray diffraction analysis, atomic force microscopy, Fourier transform infrared spectroscopy, scanning electron microscopy and energy dispersive X-ray analysis. The results revealed that the coated surface was porous, uniform and relatively well crystalline on the substrate. In vitro evaluation of the ZrO₂ coated 316L SS samples were carried out in simulated body fluid and the corrosion resistance of the ZrO₂ coated samples were examined using potentiodynamic cyclic polarisation and electrochemical impedance spectroscopy in simulated body fluid.     

Semi-quantitative chemical analysis of hard coatings by Raman micro-spectroscopy: the aluminium chromium nitride system as an example

A new method for chemical analyses of nitride-based hard coatings is presented. Raman band shifts in the spectra of Al _x Cr_1−x N coatings, deposited by physical vapour deposition from Al _x Cr_1−x targets with x _T,Al = 0, 0.25, 0.50, 0.70 and 0.85, are calibrated using compositional data of the coatings derived by elastic recoil detection analysis (ERDA) and electron probe micro-analysis (EPMA). Inserting the composition-dependent Raman shift of a combinatorial acoustic-optic lattice mode into an empirically derived equation allows the determination of Al/Cr ratios of the coating with an accuracy of about ±2%. Spot, line and area analyses of coated cemented carbide and cold work steel samples by using a computer-controlled, motorized x,y-stage are demonstrated and the most important errors influencing precision and accuracy are discussed. Figure Raman map of a coated cold-work steel sample     

Investigation of Glass-Like Sol-Gel Coatings for Corrosion Protection of Stainless Steel Against Liquid and Gaseous Attack

Glass-like sol-gel coatings have been investigated as corrosion protective coatings on stainless steel. Magnesium- and borosilicate coatings with thickness of about 100–700 nm and methyl-modified SiO2 coatings with a thickness of about 2 m were deposited on stainless steel plates by dip-coating. The coatings were densified between 400°C and 500°C in different atmospheres (N2, air) for 1 h. The corrosion protection against gaseous attack was investigated by accelerated corrosion tests, at 800°C in air for 1 h. A corrosion protection factor was calculated from the relation Fe/Fe2O3, determined by XRD on the surface of coated and uncoated samples. Methyl-modified SiO2 coatings showed a protection factor, which was 2 orders of magnitude higher than for the other coatings. Electrochemical investigations were performed on samples submerged in a NaCl solution for 200 h. The corrosion propagation, polarization resistance and impedance vector were measured. For accelerated corrosion tests, polarization intensity curves were determined for high potentials of up to 1 V. Again excellent results were obtained for the methyl-modified SiO2 coatings, which remained passive for 200 h. Results of the salt spray corrosion test, however, showed no corrosion protection by the sol-gel coatings. After 2000 h in the salt spray chamber the steel was corroded and the coatings peeled off. It is concluded that for the further development of these coatings an improved interfacial passivation will be required.     

Preparation and evaluation of carbon coated alumina as a high surface area packing material for high performance liquid chromatography

The retention of polar compounds, the separation of structural isomers and thermal stability make carbonaceous materials very attractive stationary phases for liquid chromatography (LC). Carbon clad zirconia (C/ZrO₂), one of the most interesting, exhibits unparalleled chemical and thermal stability, but its characteristically low surface area (20–30 m²/g) limits broader application as a second dimension separation in two-dimensional liquid chromatography (2DLC) where high retentivity and therefore high stationary phase surface area are required. In this work, we used a high surface area commercial HPLC alumina (153 m²/g) as a support material to develop a carbon phase by chemical vapor deposition (CVD) at elevated temperature using hexane vapor as the carbon source. The loading of carbon was varied by changing the CVD time and temperature, and the carbon coated alumina (C/Al₂O₃) was characterized both physically and chromatographically. The resulting carbon phases behaved as a reversed phase similar to C/ZrO₂. At all carbon loadings, C/Al₂O₃ closely matched the unique chromatographic selectivity of carbon phases, and as expected the retentivity was increased over C/ZrO₂. Excess carbon – the amount equivalent to 5 monolayers – was required to fully cover the oxide support in C/Al₂O₃, but this was less excess than needed with C/ZrO₂. Plate counts were 60,000–76,000/m for 5 μm particles. Spectroscopic studies (XPS and FT-IR) were also conducted; they showed that the two materials were chemically very similar.     

Electrophoretic deposition of Al2O3/ZrO2 layer with controllable thickness in ethanol medium

ZrO₂ toughened Al₂O₃ (Al₂O₃/ZrO₂) ceramic layers with required thickness were prepared by electrophoretic deposition (EPD) method using ethanol suspensions with stabilizing agent of polyethyleneimine (PEI) under constant-voltage mode in this paper. The deposition of Al₂O₃/ZrO₂ ceramic powders occurred on the titanium alloy cathode. A stable suspension with 1wt% PEI in ethanol at pH 5 was prepared in terms of the zeta potential and sedimentation of the suspension. The effects of the suspension concentration, applied voltage, deposition time and processing method of titanium alloy cathode on the coating thickness and morphology were investigated. The deposition layers on titanium alloys with smooth surfaces and thickness of 0.35?C1.2 mm could be obtained by adjusting the aforementioned parameters. In addition, after being sintered at 1500°C for 3 h in air atmosphere, ZrO₂ toughened Al₂O₃ ceramic layers became smooth and dense.     

Structure of rhenium coatings obtained by CVD

By chemical vapor deposition in the hydrogen atmosphere from Re₂(CO)₁₀ and Re(CO)₃(Cp) on steel and ceramic (C/SiC) substrates, rhenium coatings are obtained with an average thickness of 3–13 μm, when Re₂(CO)₁₀ is used, and of 2–8 μm when depositing from Re(CO)₃(Cp). The coatings are studied by X-ray diffraction and scanning electron microscopy. It is shown that when Re₂(CO)₁₀ is used, an increase in the deposition temperature results in the growth of textured coatings with preferred orientation of crystallites in the [0 0 2] direction. At the same time, a tendency for decreasing the size of rhenium crystallites is observed. With the change of evaporator temperature, the structure of Re coatings obtained from Re(CO)₃(Cp) on steel substrates changes considerably: from compact non-layered without the obvious growth direction (T _evaporator = 120°C) to a three-layer structure, where the initial layer has a compact structure followed by columnar and powdered layers (T _evaporator = 110°C). A fine compact coating is formed on ceramic substrates at an evaporator temperature of 110°C.     

Microstructure and surface residual stress of plasma sprayed nanostructured and conventional ZrO2‐8wt%Y2O3 thermal barrier coatings

The nanostructured agglomerate feedstock which can be used for plasma spraying was obtained successfully by the reconstituting nanoparticle technique. Nanostructured and conventional ZrO₂‐8wt%Y₂O₃ (8YSZ) thermal barrier coatings (TBCs) have been prepared by atmospheric plasma spraying (APS) on NiCoCrAlY coated 45# steel substrates. The microstructure and phase composition of feedstock and corresponding coating were characterized by SEM and XRD. The elastic modulus was tested by the nanoindenter instrument. The surface residual stresses were examined by XRD stress test equipment. The numerical value probability statistics of surface residual stress by the Weibull distribution theory was implemented under different thermal spray parameters. The value of residual stresses increased with increasing the thickness of the ceramic coating. The surface residual stress of nanostructured 8YSZ coating is lower than that of the conventional 8YSZ coating. A physical mechanical model is put forward to explain the causation of the variation of residual stresses. At the same time, the variation characteristic of surface residual stress is discussed by introducing the closed form solution of residual stress of laminar layer plate. Copyright © 2010 John Wiley & Sons, Ltd.     

Biocompatibility Assessment of Insulating Silicone Polymer Coatings Using an in vitro Glial Scar Assay

Vapor‐deposited silicone coatings are attractive candidates for providing insulation in neuroprosthetic devices owing to their excellent resistivity, adhesion, chemical inertness and flexibility. A biocompatibility assessment of these coatings is an essential part of the materials design process, but current techniques are limited to rudimentary cell viability assays or animal muscle implantation tests. This article describes how a recently developed in vitro model of glial scar formation can be utilized to assess the biocompatibility of vapor‐deposited silicone coatings on micron‐scale wires. A multi‐cellular monolayer comprising mixed glial cells was obtained by culturing primary rat midbrain cells on poly(D ‐lysine)‐coated well plates. Stainless steel microwires were coated with two novel insulating thin film silicone polymers, namely poly(trivinyltrimethylcyclotrisiloxane) (polyV₃D₃) and poly(trivinyltrimethylcyclotrisiloxane–hexavinyldisiloxane) (polyV₃D₃–HVDS) by initiated chemical vapor deposition (iCVD). The monolayer of midbrain cells was disrupted by placing segments of coated microwires into the culture followed by immunocytochemical analysis after 7 d of implantation. Microglial proximity to the microwires was observed to correlate with the amount of fibronectin adsorbed on the coating surface; polyV₃D₃–HVDS adsorbed the least amount of fibronectin compared to both stainless steel and polyV₃D₃. Consequently, the relative number of microglia within 100 µm of the microwires was least on polyV₃D₃–HVDS coatings compared to steel and polyV₃D₃. In addition, the astrocyte reactivity on polyV₃D₃–HVDS coatings was lower compared to stainless steel and polyV₃D₃. The polyV₃D₃–HVDS coating was therefore deemed to be most biocompatible, least reactive and most preferable insulating coating for neural prosthetic devices.

     

Photodegradation of organic compounds using chromium oxide-doped nano-sulfated zirconia

ZrO₂ is considered a huge-gap semiconductor (band gap ≈ 5 eV). To improve the visible-light photocatalytic activities of ZrO₂, an efficient Cr, SO₄ ^2? co-doped ZrO₂ photocatalyst was synthesized by the simple impregnation method followed by calcination at different calcination temperatures (300, 400, 500, and 600 °C) for 3 h. The synthesized photocatalysts were characterized by x-ray diffraction, transmission electron microscopy analysis, scanning electron microscopy analysis, energy dispersive X-ray spectroscopy analysis, FT-IR spectroscopic technique, potentiometric titration and UV–Vis spectroscopy analysis. ZrO₂ co-doped with Cr and SO₄ ^2? shows more efficiency than SO₄ ^2?-doped ZrO₂ in several aspects like surface structure, decreasing electron–hole recombination and band gap energy. The photodegradation of methylene blue dye for SO₄ ^2?-doped ZrO₂ and Cr, SO₄ ^2?-co-doped ZrO₂ has been investigated. The photocatalytic reaction confirmed that the co-doped ZrO₂ photocatalyst showed higher photocatalytic activity than mono-doped ZrO₂.     

Conduction in BaO-and MgO-doped LaGaO_3

A series of La_0.90Ba_0.10Ga_1?xMg_xO_3?α (x=0.20, 0.25 and 0.30) ceramics with a perovskite‐type orthorhombic structure were prepared by the conventional solid‐state reaction. Their conduction was studied in wet hydrogen, wet air and dry air atmospheres by various electrochemical methods including AC impedance spectroscopy, isotope effect, electrochemical hydrogen pumping, steam concentration cells and oxygen concentration cells from 873 to1273 K. Proton conduction was confirmed directly by an electrochemical hydrogen‐pumping experiment. The hydrogen evolution rates coincided with theoretical ones calculated from Faraday's law, indicating that in hydrogen atmosphere the charge carriers were predominantly protons. Isotope effect confirmed the ceramic samples possessed proton conduction under water vapor‐containing atmosphere. In wet air atmosphere, the samples were found to be mixed (proton+oxide ion+hole) conductors, and in dry air atmosphere to be mixed (oxide ion+hole) conductors. These results were different from the reports that BaO‐ and MgO‐doped LaGaO₃ ceramics were mixed conductors of oxide ion and electron hole in O₂ and air; whereas they were oxide ion conductors in N₂ and H₂ atmospheres.     

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.     

Activation of Sintering of Zirconia Ceramics by Gamma Irradiation

It was studied how gamma irradiation affects the formation of the phase composition and the properties of ZrO₂-based ceramics containing various contents of Y₂O₃, which stabilizes the tetragonal ZrO₂ phase. Gamma irradiation favored sintering and a decrease in the content of the monoclinic ZrO₂ modification. At a sintering temperature of 1250°C, ZrO₂–3 mol % Y₂O₃ ceramic with a strength of 225 MPa was obtained; this strength is half as high again as that of ceramic synthesized without irradiation.     

Characterization and corrosion resistance of organically modified silicate/MO2 (M = Zr,Ti, or Ce) hybrid coatings on a 6061‐T6 aluminum alloy

Hybrid coatings based on organically modified silicate (Ormosil)/ZrO₂ (0–1.0 wt %) and Ormosil/MO₂ (M = Ti or Ce) were synthesized through a sol–gel technique. Tetraethylenepentamine, 3‐glycidoxypropyltrimethoxysilane, tetraethoxysilane, and MO₂ (M = Zr, Ti, or Ce) metallic particle were used as precursors for the hybrid coatings. These hybrid films were deposited via spin coating onto an aluminum alloy to improve the corrosion protection. The effects induced by the ZrO₂ content and the metallic particle type on the chain dynamics, thermal stability, and corrosion performance of the coated samples were investigated. The rotating‐frame spin–lattice relaxation times and scale of the spin–diffusion path length indicated that the configuration of the hybrid films was highly crosslinked and dense and adhered to the aluminum alloy substrates. The thermal stability and the apparent activation energy, evaluated by van Krevelen's method, of the hybrid coatings depended on the ZrO₂ content and on the metallic particle type. Potentiodynamic and salt‐spray analysis revealed that the hybrid films provided exceptional barrier and corrosion protection in comparison with untreated aluminum alloy substrates. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 335–342, 2006