Corrosion resistance of amorphous AlPO4 coating in salty atmospheres

The objective of the present study was to introduce a cost-effective and environmentally friendly coating to improve the corrosion resistance of the structures located in salt water. The coating solution, based on amorphous aluminum phosphate composition, was synthesized by sol–gel process and applied to AISI 304 stainless steel by dip coating technique. X-ray diffraction, scanning electron microscopy, and energy dispersive X-ray spectroscopy analyses were employed to investigate the phase composition and morphology of the coating. Corrosion behavior of the uncoated and coated samples was investigated using standard salt spray test, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS) in 3.5 wt.% NaCl solution. Salt spray test results for the bare substrate revealed a corrosion rate of six-time greater than that of the coated surface after 168 hr exposure time. Electrochemical test results declared that the amorphous AlPO₄ coating decreased the corrosion current density of the AISI 304 stainless steel by 10 orders of magnitude. Furthermore, according to the corresponding EIS measurements, the coated surface exhibited a superior anti-corrosion performance than uncoated sample. Overall, the results declared that the amorphous AlPO₄ coating could be a good choice for surface protection of stainless steel against electrochemical corrosion in salty environments.     

Improvement of Corrosion Resistance of Metals by an Environmentally Friendly Silica Coating Method

Corrosion resistance of stainless steel and Zn plated steel can be improved by a chromium-free environmentally friendly chemical solution deposition method. Precursor solutions were prepared from tetraethoxysilane with polymer, and were deposited on stainless steel, Zn plated steel and aluminum alloy by dip coating, followed by heat treatment. Addition of polymer to the precursor solution proved very effective in preparing films free from cracks on stainless steel and aluminum alloy substrates. The corrosion resistance was greatly improved by the resulting sub-micron thick silica-polymer hybrid film coatings on stainless steel and on Zn plated steel prepared at 200°C. The hardness of aluminum alloy coated with silica-PMMA hybrid film was improved by 7% over uncoated alloy.     

Coating and Gas Permeation Properties of Urushiol-Based Organic/Inorganic Hybrid Films

The silica and urushiol based organic/inorganic hybrid was prepared with TEOS and urushiol by sol-gel process. GLYMO, as a silane-coupling agent, was used to obtain crack-free homogeneous films in various molar ratios, and to improve the adhesion between corona-treated BOPP substrate and the coatings. Two kinds of coating solutions were prepared; one was composed of TEOS and urushiol, the other was a mixture of TEOS, GLYMO and urushiol. Urushiol created less cracks on the film in a narrow range of molar ratios. As the amounts of urushiol were increased, the coating solutions quickly became heterogeneous. GLYMO was sufficient to prevent microcracks on the coated film and provided homogeneous coating solution. TEOS/urushiol and TEOS/GLYMO/urushiol coating solution gave insignificant effect on the permeability coefficients of oxygen, nitrogen and carbon dioxide, because the unsaturated alkyl side chain of urushiol might retard the formation of a dense structure between the inorganic silicate and the organic urushiol phase. From the antibacterial test of uncoating PP substrate and the coated film with hybrid solution, the reduction of bacteria of coating film was calculated to be 99.8%.     

Effect of formulation of silica‐based solution on corrosion resistance of silicate coating on hot‐dip galvanized steel

Several silica‐based solutions with 50 g/l of SiO₂ were prepared from sodium silicate solutions and silica sol; the silicate conversion coatings were obtained by immersing hot‐dip galvanized steel sheets in these solutions. These solutions were characterized using high‐resolution transmission electron microscopy and ²⁹Si nuclear magnetic resonance; the morphology of the coatings was observed by SEM and atomic force microscopy while the corrosion resistance was evaluated by electrochemical measurements as well as neutral salt spray tests. The results show that the coatings obtained from the single silica sol solution had poor adhesion and the coating obtained from the sodium silicate solution with low SiO₂/Na₂O molar ratio was uneven. By adding the silica sol to the silicate solution with low molar ratio, uniform coatings with better protection property were obtained. According to the results of ²⁹Si nuclear magnetic resonance spectra, the effects of the distribution of silicate anions with various polymerization degrees in the silica‐based solutions on the microstructure and corrosion resistance of the silicate coatings are discussed. Copyright © 2016 John Wiley & Sons, Ltd.     

Preparation of nearly monodisperse multiply coated submicrospheres with a high refractive index

Nearly monodisperse SiO2/TiO2/SiO2 multiply coated submicrospheres with nearly monodisperse silica submicrospheres as cores, thick titania layers, and thin silica skin were prepared to increase the refractive index of complex submicrospheres while keeping their near monodispersity and perfect surface properties. Nearly monodisperse colloidal silica submicrospheres as cores with a diameter of 200 nm were synthesized by a seeding technique on the basis of the hydrolysis of tetraethyl orthosilicate (TEOS) in an aqueous ethanol solution with ammonia as catalyst. On the basis of the hydrolysis of tetrabutyl orthotitanate, a procedure combining continuous feeding with multistep coating was determined to prepare titania coatings about 40 nm thick and increase the refractive index of the complex submicrospheres. The hydrolysis of TEOS was still used to get the outmost silica coating about 10 nm thick on titania coated silica submicrospheres to eliminate random aggregation caused by the TiO2 surface properties of the TiO2/SiO2 complex submicrospheres during the final fabrication of photonic crystals.     

Structure,hydrophilicity and corrosion resistance of sol–gel derived Ag-containing TiO2 film on plasma nitrided 316L stainless steel

Pure and Ag-containing TiO₂ films (Ag/Ti = 3.3 at.%) are coated on plasma nitrided 316L stainless steel by sol–gel method for biomedical applications. The addition of Ag does not cause obvious change in TG–DSC curves of the dried gels. The rough surface generated by plasma nitriding and the addition of Ag improve structural integrity of the TiO₂ films. X-ray diffraction reveals N loss and oxidation of the nitride layer during calcination treatment, and peaks of Ag or its oxides are not detected. X-ray photoelectron spectroscopy analysis indicates that Ag presents as metallic state in the film. Water contact angles of the coating samples decrease with UV irradiation treatment. The potentiodynamic polarization tests in a Ca-free Hank’s balanced salt solution show that the TiO₂ coated samples have decreased corrosion resistance due to N loss and oxidation of the nitride layer. The methods for crystallization of TiO₂ gel layers with minimized or avoided structural changes of the nitride layer will be tried in order to improve corrosion resistance of the duplex treated 316L stainless steel.     

Electrochemical Behavior of Dental Ni‐Cr Wirolloy Coated with Eco‐friendly Films in Artificial Saliva

The electrochemical corrosion behavior of the non‐precious Ni‐Cr Wirolloy, being used in dentistry, was investigated before and after applying of two types of eco‐friendly coatings, polyvinyl silsesquioxane (PVS) and nano‐hydroxyapatite (nHAP) separately in artificial saliva solution at 37 °C for 14 d of immersion. The study aimed to investigate the effectiveness of the introduced coating films in enhancing the corrosion resistance of the alloy, and in decreasing the leaching of the toxic Ni ions from the alloy into the environment. The electrochemical corrosion investigation methods used are; open circuit potential (OCP), electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization techniques. The evaluated results revealed that the electrochemically coated alloy with PVS. prepared at cathodic potential showed higher corrosion resistance and more stable film compared to that prepared by conventional dip‐coating method. At the same time, the nHAP electrochemically coated film provided the best anti‐corrosion properties over all examined time intervals. The obtained results were confirmed via surface analysis, which assured the formation of the prepared coatings on the alloy surface. Chemical analysis of the corrosion product/solutions showed that the effect of electrochemically deposited nHAP and PVS. polymer films in suppression of Ni ions leaching is similar and slightly higher than that of the chemically coated PVS. one; however, all of them are efficient in decreasing the leaching of the risky Ni ions into the solution.     

Corrosion and tribocorrosion behaviour of super‐thick diamond‐like carbon films deposited on stainless steel in NaCl solution

Super‐thick diamond‐like carbon (DLC) film is a potential protective coating in corrosive environments. In the present work, three kinds of DLC films whose thickness and modulation periods are 4 µm and 3, 21 µm and 17 and 21 µm and 7, respectively, were fabricated on stainless steel. The effect of different thickness and modulation periods on corrosion and tribocorrosion behaviour of the DLC‐coating stainless steel was investigated in 3.5 wt% NaCl aqueous solution by a ball‐on‐flat tribometer equipped with a three‐electrode electrochemical cell. The DLC‐coating stainless steel served as a working electrode, and its OCP and potentiodynamic polarization were monitored before and during rubbing. The wear–corrosion mechanism of the DLC films was investigated by SEM. The results showed that the increasing thickness can prolong significantly lifetime of DLC films in NaCl aqueous solution. In particular, the modulation period has a significant impact on the tribocorrosion resistance of the DLC super‐thick films. The study suggested that the increasing thickness of compressive stress layer could suppress film damage by reducing crack propagation rate. Thus, the super‐thick DLC film with thickness of 21 µm and 7 periods presented the best tribocorrosion resistance among all studied films. Copyright © 2016 John Wiley & Sons, Ltd.     

Multi-walled carbon nanotubes coated by multi-layer silica for improving thermal conductivity of polymer composites

Silica has been non-covalently coated on multi-walled carbon nanotubes (MWCNTs) using the sol–gel chemistry, where tetraethoxy silane (TEOS) was used to form an inorganic silica layer immediately next to surface of MWCNTs and octyl triethoxy silane was coated over the TEOS. Transmission electron microscopy (TEM) measurements show that the diameter of MWCNTs increases with increasing the number of coating layer, indicating that the silica has been coated on MWCNTs. Quantitative analysis from thermogravimetric analysis (TG) also indicates that the inorganic and organic silica has been successfully coated on MWCNTs. Further, quantitative analysis found that the amount of silica measured by TG agrees well with the increase of thickness of coated MWCNTs obtained from TEM, indicating that little or no free silica exists in the system. The thermal conductivity of epoxy/MWCNTs composite was studied and the results show that the thermal conductivity of the composite is improved by coating MWCNTs in this manner and increases with increasing the number of coatings.     

Highly transparent superhydrophobic thin film with low refractive index prepared by one-step coating of modified silica nanoparticles

An easy and effective method to prepare superhydrophobic thin film has been developed. The film with optically transparent and low refractive index was composed by one-step coating with modified silica nanoparticles. The silica nanoparticles were prepared by sol–gel process of hydrolysis and condensation of alkoxysilane compounds and then surface modification silica nanoparticles, 50 ± 10 nm, were accomplished using methoxytrimethylsilane (MOTMS). Water contact angle of film increased with the weight of MOTMS of silica sol. When the weight of MOTMS was optimized, the water contact angle and sliding angle of film were 152.8° and less than 10°, respectively. The transmittance of film was also increased as compared to the un-coated microscope glass slide, from 91 to 93.5 %. The refractive index of the film was approximately 1.09 as measured by ellipsometer. The superhydrphobic thin film was also successfully made by using spray coating and the water contact angle of this film was more than 160°. Surface morphology of difference coating methods, dip and spray, were studied. Our result suggests that the film can be applied for superhydrophobicity and optical applications.     

含氟高分子/SiO2杂化疏水材料的制备及涂层表面性质

采用自由基溶液聚合与溶胶-凝胶法相结合的方法制备了含氟高分子/SiO2杂化疏水材料.通过甲基丙烯酸十二氟庚酯(FA)与乙烯基三乙氧基硅烷(VTES)共聚合成了含氟硅共聚物(PFAS),进一步通过原硅酸乙酯(TEOS)与PFAS共聚物溶液共水解缩聚制备了具有含氟侧基的碳碳主链高分子和硅氧网络的含氟高分子/SiO2杂化疏水材料.研究结果表明,SiO2组分含量提高可以显著增加杂化材料薄膜的涂敷厚度,改善其耐久性能,而对杂化材料疏水性能的影响不大.     

Development of polyaniline – TiO2 nano composite films and its application in corrosion inhibition of oil pipelines

Oil and gas industries are the driving force of Oman’s economy and have a relatively diversified wealth among Gulf Cooperation Council Countries. Oil pipelines play an important role in transporting oil and gas from the wellheads to the processing facilities. Corrosion normally results in the deterioration of the pipe material with exposure to the surrounding environment and complete control of corrosion is difficult. Corrosion in oil transmission pipeline would be effectively addressed by introducing conventional corrosion control practices. Most of the conventional techniques are either less effective or too expensive in controlling the deterioration rate of the pipe materials. However, preventative measures may be taken to protect the metal surface from corrosion is a possible way to reduce corrosion. This research work aimed to develop a novel technique utilizing Polyaniline (PANI) and Titanium dioxide (TiO₂) nanocomposites to assess its corrosion inhibition effect on mild steel. TiO₂ was synthesized by sol-gel process. Polyaniline-Titanium dioxide (PANI/TiO₂) nanocomposites were coated on mild steel specimen by dip coating technique. The coated specimen was subjected to stability studies at different environmental conditions and exposure time. The stable thin film coated specimen was employed in the corrosion inhibition studies at various processing environments. The characteristics of TiO₂ nanoparticles and PANI-TiO₂ thin films were analyzed using Fourier Transform Infra-Red Spectroscopy (FTIR), Energy Dispersive X-Ray analysis (EDX) and X-Ray Diffraction (XRD) and Dynamic Light scattering (DLS). Scanning Electron Microscopy (SEM) was used to visualize the surface morphology and micro structural characteristics of the preformed thin layer. Potentio dynamic test, Atmosphere test and Wet/Dry tests were carried out to investigate the corrosion behaviour of coated and uncoated specimen. The study demonstrates that the Polyaniline – TiO₂ composite thin films fabricated using dip coating technique with minimum film thickness could be a feasible solution in controlling the corrosion in oil pipelines with good film stability, high durability, with a cost effective and environmentally friendly approach.     

Layer-by-layer stacked graphene nanocoatings by Marangoni self-assembly for corrosion protection of stainless steel

Graphene nanosheets are widely used in anti-corrosion polymeric coating as filler,owing to the excellent electrochemical inertness and barrier property.However,as the arrangement of graphene nanosheets is difficult to form a perfect layered structure,polymeric coating with graphene nanosheets usually needs micron-scale thickness to ensure the enhancement of corrosion protection.In this work,layer-by-layer stacked graphene nanocoatings were fabricated on stainless steel by self-assembly based on Marangoni effect.The anti-corrosion property of graphene coatings were studied through Tafel polarization curves,electrochemical impedance spectroscopy and accelerated corrosion test with extra applied voltage.The self corrosion current density of optimized three-layered graphene coated sample was one quarter of that of bare stainless steel.And the self corrosion potential of optimized sample is increased to-0.045 V.According to the results,graphene nanocoatings composed of layered nanosheets exhibits good anticorrosion property.Besides,the self-assembly method provide a promising approach to make layeredstructure coating for other researches about 2 D material nanosheets.     

Zn-Al-[V_(10)O_(28)]~(6-)双层氢氧化物掺杂对LY12铝合金表面溶胶-凝胶涂层性能的影响

采用共沉淀法制备Zn-Al-[V10O28]6-双层氢氧化物(以下简称LDH-V),研究不同添加浓度(0.0、0.25×10-3、0.75×10-3、1.5×10-3、3.0×10-3mol·L-1)的LDH-V对LY12铝合金溶胶-凝胶涂层形貌、耐蚀性的影响.采用扫描电子显微镜(SEM)和傅里叶变换红外(FTIR)光谱研究LDH-V对涂层形貌和结构的影响.运用中性盐雾实验对涂层进行耐蚀性评估.利用电化学方法对涂层在0.05 mol·L-1的NaCl溶液中的腐蚀行为进行研究.探讨加入LDH-V后溶胶-凝胶涂层的耐蚀机理.结果表明,一定量LDH-V的加入不仅可以提高溶胶-凝胶涂层的耐蚀性能,还可对涂层被破坏区域进行自修复,起到延缓铝合金基体腐蚀的作用.然而,当LDH-V的添加溶度超过一定值时,会破坏涂层的完整性并降低涂层的腐蚀防护性能.实验结果表明LDH-V最佳的添加浓度为1.5×10-3mol·L-1.     

Preparation,Characterization, and Evaluation of the Anticorrosion Performance of Submicron/Nanocarbon from Jute Sticks

Jute stick, one of the most commonly and abundantly available agricultural waste product, was converted to a value-added submicron/nano jute carbon by using pyrolysis and high-energy ball milling techniques. The submicron/nano jute carbon was characterized using FE-SEM, TEM, EDS, XRD, XPS and Raman spectroscopy. The anticorrosive performance of the submicron/nano jute carbon was investigated through electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PDP) and salt spray techniques, on mild steel plates coated with a mixture of epoxy resin and the submicron/nano jute carbon. The electrochemical impedance of the steel coated with the composite coating was two orders of magnitudes higher than that of the specimen coated with neat epoxy. Consequently, the corrosion rate of specimens coated with composite coating was 13–20 times higher than that of steel coated with neat epoxy coating. The salt spray results also indicate an improvement in the corrosion resistance performance of the composite coating compared to the neat epoxy. The uniform distribution of the submicron/nano jute carbon particles in the epoxy resin improved the denseness of the composite coating by acting as a barrier against the diffusion of chloride, moisture, and oxygen, thus, improving the corrosion resistance of the developed coating.     

Effect of thermal annealing of poly(3-octylthiophene) films covered stainless steel on corrosion properties

The effect of thermal annealing of poly(3-octylthiophene) (P3OT) coatings on the corrosion inhibition of stainless steel in an NaCl solution was investigated. P3OT was synthesized by direct oxidation of the 3-octylthiophene monomer with ferric chloride (FeCl₃) as oxidant. P3OT films were deposited by drop-casting technique onto 304 stainless steel electrode (304SS). 304SS coated with P3OT films were thermally annealed during 30 h at different temperatures (55°C, 80°C, and 100°C). The corrosion resistance of stainless steel coated with P3OT in 0.5 M NaCl aqueous solution at room temperature was investigated by using potentiodynamic polarization curves, linear polarization resistance, and electrochemical impedance spectroscopy. The results indicated that the thermal treatment at 80°C and 100°C of P3OT films improved the corrosion resistance of the stainless steel in NaCl solution; the speed of corrosion diminished in an order of magnitude with regard to the 304SS. In order to study the temperature effect in the morphology of the coatings before and after the corrosive environment and correlate it with corrosion protection, atomic force microscopy and scanning electron microscopy were used. Morphological study showed that when the films are heated, the grain size increased and a denser surface was obtained, which benefited the barrier properties of the film.     

Cerium hybrid silica coatings on stainless steel AISI 304 substrate

AISI 304 Stainless Steel is widely used in different industrial fields because of its mechanical and corrosion properties. However, its tendency to corrosion in presence of halide ions limits the applications. One strategy to improve the corrosion resistance is the use of coatings barriers containing corrosion inhibitors in their formulation. The lanthanides present attractive green and corrosion properties for the substitution of chromates, which are the most common substances used as corrosion protection. However, these compounds are highly toxic, and an intense effort is being undertaken to replace them. Cerium is a good alternative because of its relatively low cost and abundance. It fulfils the basics requirements for being considered an alternative inhibitor: the ions form insoluble hydroxides and they present low toxicity. Inorganic and hybrid sol-gel coatings have been developed to increase the corrosion resistance of metals and they provide an excellent vehicle for the incorporation of secondary phases including particles and metal ions as cerium ions. The aim of this work was to study the influence of the incorporation of cerium ions in hybrid silica sol-gel coatings deposited on AISI 304 stainless steel as substrate as a potential replacement of chromate treatments. This system should combine the barrier protection effect of silica coating with the corrosion inhibitor effect of the cerium ions inside the coatings. After 7 days of immersion in NaCl, coated substrates showed lower current densities than the bare steel, although the coatings produced from Ce (III) salts experience a slight weakening in time and those obtained from Ce (IV) chemicals evidence an enhance in the coating performance, probably due to the plugging of corrosion products in the defective areas of the film.     

Corrosion behavior of AA2024-T3 alloy treated with phosphonate-containing TEOS

Protection from corrosion of the aluminum alloy AA2024-T3 coated with a tetraethoxysilicate (TEOS)/aminotrimethyllenephosphonic acid (ATMP) film in a 0.05-mol L⁻¹ NaCl solution was evaluated using electrochemical impedance spectroscopy, scanning electron microscopy, energy disperse spectroscopy, and atomic force microscopy. The present work investigates the influence of different pretreatment procedures of the alloy surface and the ATMP concentration on the corrosion resistance of the coated samples. The undoped sol–gel coatings did not provide adequate corrosion protection. The best corrosion protection was achieved using acetic acid pretreatment and subsequent deposition of an ATMP-modified TEOS film with an optimal concentration of 5.00 × 10⁻⁴ mol L⁻¹ in the deposition bath. The acetic acid pretreatment promotes a decrease in galvanic corrosion and the surface enrichment of aluminum favoring the metalosiloxane and the metal–phosphonic bonds with increasing likely reaction sites, thus promoting the formation of a more homogeneous and compact coating with improved resistance.     

An Electrochemical Study on the Corrosion Inhibition of Stainless Steel by Polyaniline Film

Polyaniline(PANI)film was electrosynthesized on 304 stainless steel by cyclic voltammetry using aqueous oxalic acid as supporting electrolyte.The potential sweep rates were changed to achieve the PANI film with different thickness and structures.Protective properties of the PANI film for corrosion of stainless steel in 3% NaC1 aqueous solution were investigated by monitoring potentiodynamic polarization curves and electrochemical impedance spectroscopy(EIS).The results showed that the PANI film which was formed with lower sweep rate led to more positive shift of corrosion potential and greater charge transfer resistance,reflecting higher inhibition for corrosion of the stainless steel.     

Rapid one-step synthesis, characterization and functionalization of silica coated gold nanoparticles

This paper describes a rapid, simple and one-step method for preparing silica coated gold (Au@SiO₂) nanoparticles with fine tunable silica shell thickness and surface functionalization of the prepared particles with different groups. Monodispersed Au nanoparticles with a mean particle size of 16 nm were prepared by citrate reduction method. Silica coating was carried out by mixing the as prepared Au solution, tetraethoxysilane (TEOS) and ammonia followed by microwave (MW) irradiation. Although there are several ways of coating Au nanoparticles with silica in the literature, each of these needs pre-coating step as well as long reaction duration. The present method is especially useful for giving the opportunity to cover the colloidal Au particles with uniform silica shell within very short time and forgoes the use of a silane coupling agent or pre-coating step before silica coating. Au@SiO₂ nanoparticles with wide range of silica shell thickness (5-105 nm) were prepared within 5 min of MW irradiation by changing the concentration of TEOS only. The size uniformity and monodispersity were found to be better compared to the particles prepared by conventional methods, which were confirmed by dynamic light scattering and transmission electron microscopic techniques. The prepared Au@SiO₂ nanoparticles were further functionalized with amino, carboxylate, alkyl groups to facilitate the rapid translation of the nanoparticles to a wide range of end applications. The functional groups were identified by XPS, and zeta potential measurements.