Passivation is a frequently used method to strengthen the surface of aluminum alloys. This study fabricated two zirconium-rich passive layers on the Al alloy. The morphology, thickness, and chemical composition of the prepared coating were analyzed employing XPS and TEM. Electrochemical impedance spectroscopy and Tafel polarization tests are also used to assess the anticorrosive performance. The passivation layers exhibit a dual-layer structure, with thicknesses ranging from 16 nm to 26 nm. Chemical composition of the two component layers is different. Electrochemical tests confirm a significant improvement in anticorrosive performance for both passivated samples compared to the untreated substrate. The study offers insights into the bonding mechanisms and layered architecture of the passivation film, contributing to the development of non-toxic, high-performance surface treatment technologies for aluminum alloys.
HouBLuD. Corrosion cost and preventive strategies in China. BCAS2018; 33: 601–609.
2.
SarukasanDThirumavalavanK. Investigations of surface characteristics on AA5083 alloy with dual treatment. Surf Eng2025; 41: 279–292.
3.
XueYPengCWangY, et al.Effects of Mo addition on anti-corrosion and mechanical properties of Al coating deposited sintered Nd-Fe-B magnets. Surf Eng2025; 666: 123727.
4.
LiuJZhangHChenB, et al.Structure and properties of aluminum alloy composite conversion coating. Surf Eng2024; 40: 1088–1097.
5.
FrankowskiPKMatysikS. Integrating electromagnetic NDT and IoT for enhanced structural health monitoring of corrosion in reinforced concrete as a key to sustainable smart cities. Sustainability2025; 17: 10307.
6.
HanHMJiangLHanB, et al.Simultaneously increasing the mechanical properties and corrosion resistance of B4C/Al4C/Al composites via forming “TiO2-Al” interfacial layer. Surf Eng2024; 50: 33065–33076.
7.
AkbarAChoiGNjorogeJM, et al.Cloud-based database framework of corrosion detecting and grading for temporary steel pipe supports. J Asian Arch Build Eng2025; 26: 1–17.
8.
ChenYFuHSunY, et al.Study on the superhydrophobic coatings with antifouling and anticorrosion properties. Surf Eng2024; 40: 196–205.
9.
YadavLSihmarAKumarS, et al.Review of nano-based smart coatings for corrosion mitigation: mechanisms, performance, and future prospects. Environ Sci Pollut Res2025; 32: 17032–17058.
10.
CuiTWuJSongJ, et al.Atmospheric corrosion behavior of typical aluminum alloys in low-temperature environment. Metals (Basel)2025; 15: 277.
11.
ShehabeldeenTAElMehassebIMMostafaYS, et al.Chromium oxide/cerium oxide nanocoating and thermal treatment to enhance the corrosion resistance of 2024-T3 aluminum alloy for industrial applications. ChemistrySelect2025; 10: e05096.
12.
KulikovBPartykoEKosovichA, et al.Analysis of composition, properties, and usage efficiency of different commercial salt fluxes for aluminum alloy refining. Metals (Basel)2025; 15: 448.
13.
LiDXuXTianP, et al.Chemical deoxidation with Cr-free solution for less-polluting pretreatment of aviation aluminium alloy. Corros Eng Sci Technol2025; 60: 3–12.
14.
LengBXueYLiJ, et al.A critical review of anti-corrosion chemical surface treatment of aluminum alloys used for sports equipment. Crystals (Basel)2024; 14: 101.
15.
ZhuWLiaoZYiA, et al.The effect of Ti/Zr conversion coating drying temperature on the adhesive strength of organic coating. Guangdong Chem Ind2020; 47: 14–17+23.
16.
ShiQWangSShiS, et al.Formation mechanism of passivation layer under air exposure on TiZrV non-evaporable getter film. J Phys Chem C2024; 128: 1034–1048.
17.
QinZLiH. A novel fluorine-titanate conversion process on 6061 aluminum alloy surface. CPC2014; 35: 742–745.
18.
FkiriASaidaniMAChoukW, et al.Facile modified sol-gel process to prepare highly photocatalytic active ZrO2 nanoparticles: microstructure and optical properties. J Sol-Gel Sci Technol2025; 115: 487–497.
19.
QuanYZhangNZhangZ, et al.Enhanced performance of Ni catalysts supported on ZrO2 nanosheets for CO2 methanation: effects of support morphology and chelating ligands. Int J Hydrogen Energy2021; 46: 14395–14406.
20.
SinhaSBadrinarayananSSinhaAPB. Interaction of oxygen with Zr76Fe24 metglass: an X-ray photoelectron spectroscopy study. J Less Common Met1986; 125: 85–95.
21.
MorantCSanzJMGalanL, et al.An XPS study of the interaction of oxygen with zirconium. Surf Sci1989; 218: 331–345.
VorobevASSuzdaltsevAVGalashevAE. Binding energies in the molten M-Al-Zr-O-F systems (M=Li, Na, K). Russian Metall (Metally)2019; 8: 781–786.
24.
MaoPZhaoRLiS, et al.Electrochemical behavior of zirconium ions regulated by fluoride ions revisited. J Mol Liq2025; 425: 127254.
25.
SanjaMŠoićIŠpadaV. Unified equivalent circuit of dielectric permittivity and porous coating formalisms for EIS probing of thick industrial grade coatings. Prog Org Coat2021; 153: 106155.
26.
DhawanSKBhandariHRuhiG, et al.Corrosion preventive materials and corrosion testing. Boca Raton, FL: CRC Press, 2020.
27.
MartinKScullyJ. Basic aspects of electrochemical impedance application for the life prediction of organic coatings on metals. Corrosion1990; 46: 22–29.
28.
WangQZhangRRenX, et al.Sustainable pH-responsive Ce–Tb–BTC@ PDA composite for smart coatings with dual functionality: corrosion reporting and active protection. ACS Appl Mater Interfaces2025; 17: 54041–54056.
29.
FanCLiuYYinX, et al.Electrochemical behavior and interfacial delamination of a polymer-coated galvanized steel system in acid media. ACS omega2021; 6: 20331–20340.
30.
KassinisCArestiLKoronidesM, et al.A review on the environment’s influence on coastal marine steel corrosion and in-situ monitoring. J Mater Sci Mater Eng2025; 20: 125.
31.
WuJWangQWangR, et al.Gradient adsorption-metal activation interface engineering for Co/Co2 methanation: Al-Zr coordination regulation and multi-scale synergistic mechanism. Available at SSRN 5391848.
32.
WangZOuyangCFengZ, et al.Preparation of γ-GPS-ZrO2 hybrid coating by sol-gel method and its synergistic enhancement effect on corrosion resistance and adhesion of AA2024 aluminum alloy. J Sol-Gel Sci Technol2025; 116: 1432–1450.
33.
XuLHuangH. Anti-corrosion properties of a silane film on Q235 steel in a 3.5 wt.% NaCl solution. Corros Eng Sci Technol2025; 60: 406–419.
34.
SihlerSZienerU. Silica nanoparticles vs nanocapsules from dye-stabilized emulsions: role of the comonomer. Langmuir2025; 41: 15164–15172.
35.
HanischNDittesASteinertP, et al.Quantitative design criterion for mechanical interface functionalization regarding adhesion strength in chemically pre-treated polymer-metal hybrids using fractal dimension. J Adhes2025; 101: 795–813.
36.
ZhongYLiuYYangX, et al.Sio2/polydopamine photothermal superhydrophobic coating with good anti-icing performance. Surf Eng2024; 40: 907–916.
37.
DingYLiYLiuH, et al.Corrosion evolution behavior of Ti/Zr/oligomeric epoxy silane composite chemical conversion coatings on multi-metals. Acta Metall Sin (English Letters)2025; 38: 889–903.
38.
ZhangQPanLLyuX, et al.Regulation of pyrolysis behavior in Si-Zr-Al-Y system by sugarcane peel-derived templates: Phase evolution, thermal stability and low thermal conductivity of ceramic aerogels. Available at SSRN 5564936.
39.
TangXXieFLuY, et al.Halide-based solid electrolytes: opportunities and challenges in the synergistic development of all-solid-state Li/Na batteries. EES Batteries2025; 1: 1481–1501.
40.
WangMChenJAhmadZ, et al.High-temperature resistance and thermal insulation performance of continuous SiMOC ceramic fibers fabricated by the modified sol-gel method combined with dry spinning. J Sol-Gel Sci Technol2025; 113: 427–437.
41.
LiSWanHLinJ, et al.Materials & design physicochemical interactions between amorphous metal oxide and polymer in metal - polymer hybrid materials. Mater Des2023; 230; 111993.
