Enhancement of the hydrophobic and anti-corrosion properties of a composite zeolite coating on Al6061 substrate by modification of silane matrix

Abstract

Anti-corrosion properties of a silane–zeolite composite coating applied to aluminium substrates have been investigated. The composite film was prepared with different silane matrix formulations (varying bi-functional and tri-functional silane ratios). The results showed high hydrophobicity of the modified silane–zeolite coatings. Corrosion protection performance, during immersion in 3.5% NaCl solution, was evaluated by means of polarisation and electrochemical impedance spectroscopy tests. The polarisation curves evidenced a good corrosion resistance of all composite coating; though at high content of bi-functional silane, a reduction of corrosion protection performance was observed. At long immersion time (until 150 days), only the composite coating with low amount of bi-functional silane still evidenced good barrier properties.

Keywords

Aluminium Silane coating Zeolite Electrochemical characterisation Hydrophobicity

Get full access to this article

View all access options for this article.

References

Zheng

and Li

: ‘Inorganic–organic sol gel hybrid coatings for corrosion protection of metals’, J. Sol-Gel Sci. Technol. 2010 54 174–187. doi: 10.1007/s10971-010-2173-1.

Xue

C.-H.

Jia

S.-T.

Zhang

and Ma

J.-Z.

: ‘Large-area fabrication of superhydrophobic surfaces for practical applications: an overview’, Sci. Technol. Adv. Mater. 2010 11 033002. doi: 10.1088/1468-6996/11/3/033002.

Koene

B. E.

Shah

P. B.

, and Brinker

J. C.

: ‘ Hydrophobic organic–inorganic hybrid silane coatings, US 2008/0113188 A1’, 2008.

Naderi

Fedel

Deflorian

Poelman

and Olivier

: ‘Synergistic effect of clay nanoparticles and cerium component on the corrosion behavior of eco-friendly silane sol-gel layer applied on pure aluminum’, Surf. Coat. Technol. 2013 224 93–100. doi: 10.1016/j.surfcoat.2013.03.005.

Montemor

M. F.

Cabral

A. M.

Zheludkevich

M. L.

and Ferreira

M. G. S.

: ‘The corrosion resistance of hot dip galvanized steel pretreated with bis-functional silanes modified with microsilica’, Surf. Coat. Technol. 2006 200 2875–2885. doi: 10.1016/j.surfcoat.2004.11.012.

Zandi Zand

Verbeken

and Adriaens

: ‘Evaluation of the corrosion inhibition performance of silane coatings filled with cerium salt-activated nanoparticles on hot-dip galvanized steel substrates’, Int. J. Electrochem. Sci. 2013 8 4927–4940.

Zandi-Zand

Ershad-Langroudi

and Rahimi

: ‘Silica based organic–inorganic hybrid nanocomposite coatings for corrosion protection’, Prog. Org. Coat. 2005 53 286–291. doi: 10.1016/j.porgcoat.2005.03.009.

Snihirova

Lamaka

S. V.

Taryba

Salak

A. N.

Kallip

Zheludkevich

M. L.

Ferreira

M. G. S.

and Montemor

M. F.

: ‘Hydroxyapatite microparticles as feedback-active reservoirs of corrosion inhibitors’, ACS Appl. Mater. Interfaces 2010 2 3011–3022. doi: 10.1021/am1005942.

van Ooij

W. J.

Zhu

Stacy

Seth

Mugada

Gandhi

and Puomi

: ‘Corrosion protection properties of organofunctional silanes – an overview’, Tsinghua Sci. Technol. 2005 10 639–664. doi: 10.1016/S1007-0214(05)70134-6.

10.

Zhu

and van Ooij

W. J.

: ‘Corrosion protection of AA 2024-T3 by bis-3-(triethoxysilyl) propyl]tetrasulfide in sodium chloride solution. Part 2: mechanism for corrosion protection’, Corros. Sci. 2003 45 2177–2197. doi: 10.1016/S0010-938X(03)00061-1.

11.

Kawai

and Tsutsumi

: ‘Reactivity of silanol groups on zeolite surfaces’, Colloid Polym. Sci. 1998 276 992–998. doi: 10.1007/s003960050338.

12.

Cai

and Yan

: ‘Corrosion-resistant zeolite coatings’, Corrosion 2008 64 271–278. doi: 10.5006/1.3278471.

13.

Calabrese

Bonaccorsi

and Proverbio

: ‘Corrosion protection of aluminum 6061 in NaCl solution by silane–zeolite composite coatings’, J. Coat. Technol. Res. 2012 9 597–607. doi: 10.1007/s11998-011-9391-5.

14.

Calabrese

Bonaccorsi

Caprì

and Proverbio

: ‘Adhesion aspects of hydrophobic silane zeolite coatings for corrosion protection of aluminium substrate’, Prog. Org. Coat. 2014 77 1341–1350. doi: 10.1016/j.porgcoat.2014.04.025.

15.

Mekeridis

E. D.

Kartsonakis

I. A.

Pappas

G. S.

and Kordas

G. C.

: ‘Release studies of corrosion inhibitors from cerium titanium oxide nanocontainers’, J. Nanopart. Res. 2011 13 541–554. doi: 10.1007/s11051-010-0044-x.

16.

Caprì

Calabrese

Bonaccorsi

and Proverbio

: ‘Corrosion resistance of cerium based silane-zeolite coatings on AA6061’, Solid State Phenom. 2015 227 163–166. http://www.scientific.net/SSP.227.163, (accessed 3 February 2015). doi: 10.4028/www.scientific.net/SSP.227.163

17.

Dias

S. A. S.

Lamaka

S. V.

Nogueira

C. A.

Diamantino

T. C.

and Ferreira

M. G. S.

: ‘Sol-gel coatings modified with zeolite fillers for active corrosion protection of AA2024’, Corros. Sci. 2012 62 153–162. doi: 10.1016/j.corsci.2012.05.009.

18.

Larsen

S. C.

: ‘Nanocrystalline zeolites and zeolite structures: synthesis, characterization and applications’, J. Phys. Chem. C 2007 111 18464–18474. doi: 10.1021/jp074980 m.

19.

Lee

J. Y.

Lee

S. H.

and Kim

S. W.

: ‘Surface tension of silane treated natural zeolite’, Mater. Chem. Phys. 2000 63 251–255. doi: 10.1016/S0254-0584(99)00231-X.

20.

Calabrese

Bonaccorsi

Caprì

and Proverbio

: ‘Electrochemical behavior of hydrophobic silane–zeolite coatings for corrosion protection of aluminum substrate’, J. Coatings Technol. Res. 2014 11 883–898. doi: 10.1007/s11998-014-9597-4.

21.

Yue

Y. Y.

Liu

Z. X.

Wan

T. T.

and Wang

P. C.

: ‘Effect of phosphate-silane pretreatment on the corrosion resistance and adhesive-bonded performance of the AZ31 magnesium alloys’, Prog. Org. Coat. 2013 76 835–843. doi: 10.1016/j.porgcoat.2013.01.010.

22.

Freni

Frazzica

Dawoud

Chmielewski

Calabrese

and Bonaccorsi

: ‘Adsorbent coatings for heat pumping applications: verification of hydrothermal and mechanical stabilities’, Appl. Therm. Eng. 2013 50 1658–1663. doi: 10.1016/j.applthermaleng.2011.07.010.

23.

Bonaccorsi

Calabrese

Freni

Proverbio

and Restuccia

: ‘Zeolites direct synthesis on heat exchangers for adsorption heat pumps’, Appl. Therm. Eng. 2013 50 1590–1595. doi: 10.1016/j.applthermaleng.2011.10.028.

24.

Villar

M. A.

Bibbo

M. A.

and Valles

E. M.

: ‘Influence of pendant chains on mechanical properties of model poly(dimethylsiloxane) networks. 1. Analysis of the molecular structure of the Network’, Macromolecules 1996 29 4072–4080. doi: 10.1021/ma9506593.

25.

Oprea

: ‘Structure and properties of cross-linked polyurethane copolymers’, Adv. Polym. Technol. 2009 28 165–172. doi: 10.1002/adv.20155.

26.

Pizzi

and Mittal

K. L.

: ‘ Handbook of adhesive technology, revised and expanded ’, 2003

New York

CRC Press.

27.

Bonaccorsi

Proverbio

Freni

and Restuccia

: ‘In situ growth of zeolites on metal foamed supports for adsorption heat pumps’, J. Chem. Eng. Japan 2007 40 1307–1312. doi: 10.1252/jcej.07WE174.

28.

Plueddemann

E. P.

: ‘ Silane coupling agents ’, 2nd edn 1991

New York

Plenum Press.

29.

Correa-Borroel

A. L.

Gutierrez

Arce

Cabrera-Sierra

and Herrasti

: ‘Organosilanes and polypyrrole as anticorrosive treatment of aluminium 2024’, J. Appl. Electrochem. 2009 39 2385–2395. doi: 10.1007/s10800-009-9925-z.

30.

Cassie

A. B. D.

and Baxter

: ‘Wettability of porous surfaces’, Trans. Faraday Soc. 1944 40 546–551. doi: 10.1039/tf9444000546.

31.

Guan

H. M.

Chung

T. S.

and Kulprathipanja

: ‘Effects of novel silane modification of zeolite surface on polymer chain rigidification and partial pore blockage in polyethersulfone (PES)-zeolite A mixed matrix membranes’, J. Membr. Sci. 2006 275 17–28. doi: 10.1016/j.memsci.2005.08.015.

32.

Matsumoto

Tsutsumi

Schumacher

and Unger

K. K.

: ‘Surface functionalization and stabilization of mesoporous silica spheres by silanization and their adsorption characteristics’, Langmuir 2002 18 4014–4019. doi: 10.1021/la020004c.

33.

Calabrese

Bonaccorsi

Caprì

and Proverbio

: ‘Enhancement of the mechanical properties of a zeolite based composite coating on aluminium substrate by silane matrix modification’, Ind. Eng. Chem. Res. 2016 55 6952–6960. doi: 10.1021/acs.iecr.6b00844.

34.

Pourbaix

: ‘Atlas of electrochemical equilibria in aqueous solutions’, Cebelcor 1974.

35.

Zhu

and van Ooij

W. J.

: ‘Corrosion protection of AA 2024-T3 by bis-3-(triethoxysilyl)propyl]tetrasulfide in sodium chloride solution’, Corros. Sci. 2003 45 2177–2197. doi: 10.1016/S0010-938X(03)00061-1.

36.

Andreatta

Aldighieri

Paussa

Di Maggio

Rossi

and Fedrizzi

: ‘Electrochemical behaviour of ZrO₂ sol-gel pre-treatments on AA6060 aluminium alloy’, Electrochim. Acta 2007 52 7545–7555. doi: 10.1016/j.electacta.2006.12.065.

37.

Frignani

Zucchi

Trabanelli

and Grassi

: ‘Protective action towards aluminium corrosion by silanes with a long aliphatic chain’, Corros. Sci. 2006 48 2258–2273. doi: 10.1016/j.corsci.2005.06.018.

38.

Cabral

A. M.

Duarte

R. G.

Montemor

M. F.

and Ferreira

M. G. S.

: ‘A comparative study on the corrosion resistance of AA2024-T3 substrates pre-treated with different silane solutions: composition of the films formed’, Prog. Org. Coat. 2005 54 322–331. doi: 10.1016/j.porgcoat.2005.08.001.

39.

Matysik

F. M.

Schulze

K. D.

and Einicke

W. D.

: ‘Impedance spectroscopic investigations of zeolite-polydimethylsiloxane electrodes’, Electrochim. Acta 2002 48 297–301. doi: 10.1016/S0013-4686(02)00666-7.

40.

Palomino

L. M.

Suegama

P. H.

Aoki

I. V.

Montemor

M. F.

and De Melo

H. G.

: ‘Electrochemical study of modified cerium-silane bi-layer on Al alloy 2024-T3’, Corros. Sci. 2009 51 1238–1250. doi: 10.1016/j.corsci.2009.03.012.

41.

W. G.

J. M.

Zhang

J. Q.

and Cao

C. N.

: ‘Reducing the water absorption in epoxy coatings by silane monomer incorporation’, Corros. Sci. 2006 48 3731–3739. doi: 10.1016/j.corsci.2006.02.005.

42.

Montemor

M. F.

Simões

A. M.

Ferreira

M. G. S.

Williams

and Edwards

: ‘Corrosion performance of organosilane based pre-treatments for coatings on galvanized steel’, Prog. Org. Coat. 2000 38 17–26. doi: 10.1016/S0300-9440(99)00080-6.

43.

Ferreira

M. G. S.

Duarte

R. G.

Montemor

M. F.

and Simões

A. M. P.

: ‘Silanes and rare earth salts as chromate replacers for pre-treatments on galvanised steel’, Electrochim. Acta 2004 49 2927–2935. doi: 10.1016/j.electacta.2004.01.051.

44.

Zhu

and van Ooij

W. J.

: ‘Enhanced corrosion resistance of AA 2024-T3 and hot-dip galvanized steel using a mixture of bis-triethoxysilylpropyl]tetrasulfide and bis-trimethoxysilylpropyl]amine’, Electrochim. Acta 2004 49 1113–1125. doi: 10.1016/j.electacta.2003.10.023.

45.

Yamamoto

Sugiyama

Matsuoka

Kohmura

Honda

Banno

and Nozoye

: ‘Dissolution of zeolite in acidic and alkaline aqueous solutions as revealed by AFM Imaging’, J. Phys. Chem. 1996 100 18474–18482. doi: 10.1021/jp961583v.

46.

Palanivel

Zhu

and van Ooij

W. J.

: ‘Nanoparticle-filled silane films as chromate replacements for aluminum alloys’, Prog. Org. Coat. 2003 47 384–392. doi: 10.1016/j.porgcoat.2003.08.015.

47.

Trabelsi

Triki

Dhouibi

Ferreira

M. G. S.

Zheludkevich

M. L.

and Montemor

M. F.

: ‘The use of pre-treatments based on doped silane solutions for improved corrosion resistance of galvanised steel substrates’, Surf. Coat. Technol. 2006 200 4240–4250. doi: 10.1016/j.surfcoat.2005.01.044