Ordering and disordering of in situ grown MgAl-layered double hydroxide and its effect on the structural and corrosion resistance properties

A MgAl-layered double hydroxide(MgAl-LDH) protective film was developed on AA6082 substrates via the in situ hydrothermal growth method to obtain a distinct cauliflower-like LDH structure, and coated substrates were further heat-treated in air at temperatures from 100 to 250℃ to further improve the corrosion resistance of MgAl-LDH by taking advantage of the LDH memory effect; also, the effect of calcination on MgAl-LDH structural stability and the corresponding corrosion resistance properties were investigated. The structural characterization of uncalcined and calcined LDH films were examined using scanning electron microscopy, energy-dispersive spectroscopy, X-ray diffraction, thermogravimetric analysis, differential scanning calorimetry, and Fourier transform infrared spectroscopy. The corresponding corrosion protection efficiency of the developed coating was studied through potentiodynamic polarization experiments and by electrochemical impedance spectroscopy. Compared with uncalcined MgAl-LDH, the calcined film showed a relatively lower corrosion current density and a higher impedance value, especially after heat treatment at 250℃. The findings demonstrate that calcination strongly affects the oriented growth of the LDH and causes an increase in the surface area and contraction of the basal spacing, which in turn caused a compact structure that substantially influenced the LDH corrosion resistance properties.     

PLGA/硬石复合涂层镁基纳米复合材料在植入应用时的体外生物活性和腐蚀行为

A type of polymer/ceramic coating was introduced on a magnesium-based nanocomposite, and the nanocomposite was evaluated for implant applications. The microstructure, corrosion, and bioactivity of the coated and uncoated samples were assessed. Mechanical alloying followed by sintering was applied to fabricate the Mg–3Zn–0.5Ag–15NiTi nanocomposite substrate. Moreover, different contents of poly(lactic-co-glycolic acid) (PLGA) coatings were studied, and 10wt% of PLGA content was selected. The scanning electron microscopy (SEM) images of the bulk nanocomposite showed an acceptable homogenous dispersion of the NiTi nanoparticles (NPs) in the Mg-based matrix. In the in vitro bioactivity evaluation, following the immersion of the uncoated and coated samples in a simulated body fluid (SBF) solution, the Ca/P atomic ratio demonstrated that the apatite formation amount on the coated sample was greater than that on the uncoated nanocomposite. Furthermore, assessing the corrosion resistance indicated that the coatings on the Mg-based substrate led to a corrosion current density (i_corr) that was considerably lower than that of the substrate. Such a condition revealed that the coating would provide an obstacle for the corrosion. Based on this study, the PLGA/hardystonite (HT) composite-coated Mg–3Zn–0.5Ag–15NiTi nanocomposite may be suitably applied as an orthopedic implant biomaterial.     

Antibacterial properties and corrosion resistance of AISI 420 stainless steels implanted by silver and copper ions

Silver or copper ions are often chosen as antibacterial agents. But a few reports are concerned with these two antibacterial agents for preparation of antibacterial stainless steel (SS). The antibacterial properties and corrosion resistance of AISI 420 stainless steel implanted by silver and copper ions were investigated. Due to the cooperative antibacterial effect of silver and copper ions, the Ag/Cu implanted SS showed excellent antibacterial activities against both Gram-negative Escherichia coli (E. coli) and Gram-positive Staphylococcus aureus (S. aureus) at a total implantation dose of 2×1017 ions/cm2. Electrochemical polarization curves revealed that the corrosion resistance of Ag/Cu implanted SS was slightly enhanced as compared with that of un-implanted SS. The implanted layer was characterized by X-ray photoelectron spectroscopy (XPS). Core level XPS spectra indicate that the implanted silver and copper ions exist in metallic state in the implanted layer.     

Effects of cupric ions on the corrosion behavior of aluminum alloy 5A02 in ethylene glycol-water solution

The effects of cupric ions on the corrosion behavior of aluminum alloy 5A02 in ethylene glycol-water solutions were studied by potentiodynamic polarization, electrochemical noise (EN), and complementary techniques including scanning electron microscopy (SEM), atomic force microscopy (AFM), and X-ray photoelectron spectroscopy (XPS). A positive corrosion potential and increased corrosion current were observed due to the deposition of copper. The results demonstrate that the main corrosion type was pitting and the increasing cupric ion concentration augmented the pitting density. The pits became larger and deeper as a result of the embedment of copper into the surface of the alloy. Cupric ions were preferentially deposited at the defects around the secondary phase, leading to the formation of Al-Cu microgalvanic couples, which increased the corrosion rate. The corrosion rate gradually reached a stable value as the concentration of cupric ions was increased beyond 10 mmol/L.     

Microstructure and corrosion resistance of Fe/Mo composite amorphous coatings prepared by air plasma spraying

Fe/Mo composite coatings were prepared by air plasma spraying (APS) using Fe-based and Mo-based amorphous and nanocrystalline mixed powders. Microstructural studies show that the composite coatings present a layered structure with low porosity due to adding the self-bonded Mo-based alloy. Corrosion behaviors of the composite coatings, the Fe-based coatings and the Mo-based coatings were investigated by electrochemical measurements and salt spray tests. Electrochemical results show that the composite coatings exhibit a lower polarization current density and higher corrosion potentials than the Fe-based coating when tested in 3.5wt% NaCl solutions, indicating superior corrosion resistance compared with the Fe-based coating. Also with the increase in addition of the Mo-based alloy, a raised corrosion resistance, inferred by an increase in corrosion potential and a decrease in polarization current density, can be found. The results of salt spray tests again show that the corrosion resistance is enhanced by adding the Mo-based alloy, which helps to reduce the porosity of the composite coatings and enhance the stability of the passive films.     

Hydrothermal synthesis and corrosion behavior of the protective coating on Mg-2Zn-Mn-Ca-Ce alloy

Protective coatings were synthesized on the Mg-2Zn-Mn-Ca-CeMg alloy through the hydrothermal method with de-ionized water as the reagent. The coatings were composed of Mg hydroxide, generally uniform and compact.Hydrogen evolution tests and electrochemical tests in the Hanks' solution demonstrated that the Mg(OH)_2coatings effectively decreased the bio-degradation rate of the Mg alloy substrate. Microstructure observation showed that the coating formation on the secondary phases was more difficult than that on the α-Mg matrix,which led to micro cracks and pores on the secondary phases after drying. Over synthesizing time, the coating layer on secondary phases gradually becomes more compact and uniform. Meanwhile, owing to the thicker and more compact coatings, the corrosion resistance and protective efficiency were significantly improved with longer synthesizing time as well.     

Corrosion behavior of Ni–P/nano-TiC composite coating prepared in electroless baths containing different types of surfactant

In current research, in order to enhance the incorporation of nano-sized TiC particles into electroless Ni–P (EN) coating, different types of surfactant (cationic, anionic, and polymeric) were added to the plating bath. The effects of addition of the surfactants on surface morphology, deposition rate, TiC and P contents of the prepared coatings were investigated. The surface morphology was evaluated by scanning electron microscopy (SEM). It was demonstrated that in the presence of the anionic, polymeric and somehow cationic surfactants, TiC nano-particles were embedded in the matrix which influenced the surface morphology. The effect of surfactant types on the corrosion properties of Ni–P/TiC coated steel was also studied. Corrosion behavior of the coated steel was evaluated by potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) which affected by the incorporation of TiC particles into the Ni–P matrix. The level of corrosion resistance improvement depended largely on the phosphorous and TiC concentration of the applied coating.     

Microstructural analysis and hot corrosion behavior of HVOF-sprayed Ni–22Cr–10Al–1Y and Ni–22Cr–10Al–1Y–SiC(N) coatings on ASTM-SA213-T22 steel

The present paper deals with the investigation of microstructure and high-temperature hot corrosion behavior of high-velocity oxy fuel(HVOF)-produced coatings. Two powder coating compositions, namely, Ni22Cr10Al1Y alloy powder and Ni22Cr10Al1Y(80 wt%; microsized)–silicon carbide(SiC)(20 wt%; nano(N)) powder, were deposited on a T-22 boiler tube steel. The hot corrosion behavior of bare and coated steels was tested at 900°C for 50 cycles in Na_2SO_4–60 wt%V_2O_5 molten-salt environment. The kinetics of corrosion was established with weight change measurements after each cycle. The microporosity and microhardness of the as-coated samples have been reported. The X-ray diffraction,field emission-scanning electron microscopy/energy dispersive spectroscopy, and X-ray mapping characterization techniques have been utilized for structural analysis of the as-coated and hot-corroded samples. The results showed that both coatings were deposited with a porosity less than2%. Both coated samples revealed the development of harder surfaces than the substrate. During hot corrosion testing, the bare T22 steel showed an accelerated corrosion in comparison with its coated counterparts. The HVOF-sprayed coatings were befitted effectively by maintaining their adherence during testing. The Ni22Cr10Al1Y–20 wt%SiC(N) composite coating was more effective than the Ni–22Cr–10Al–1Y coating against corrosion in the high-temperature fluxing process.     

Effect of pickling processes on the microstructure and properties of electroless Ni–P coating on Mg–7.5Li–2Zn–1Y alloy

The electroless plating Ni–P is prepared on the surface of Mg–7.5Li–2Zn–1Y alloys with different pickling processes.The microstructure and properties of Ni–P coating are investigated.The results show that the Ni–P coatings deposited using the different pickling processes have a different high phosphorus content amorphous Ni–P solid solution structure,and the Ni–P coatings exhibit higher hardness.There is higher phosphorus content of Ni–P amorphous coating using 125 g/L Cr O3and 110 ml/L HNO3(w68%)than using 180 g/L Cr O3and 1 g/L KF during pre-treatment,and the coating structure is more compact,and the Ni–P coatings exhibit more excellent adhesion with substrate(Fcup to22 N).The corrosion potential of Ni–P coating is improved and exhibits good corrosion resistance.As a result,Mg-7.5Li-2Zn-1Y alloy is remarkably protected by the Ni–P coating.     

Effect of nano-SiC particles on the corrosion resistance of NiP-SiC composite coatings

NiP-SiC (≈1 1wt% P) composite coatings were electroplated in a Brenner type plating bath. The coatings had amorphous nano-phase composite structure. Direct current and alternating current electrochemical tests were carried out on such coatings in a 3.5wt% solution of NaCl to evaluate their corrosion resistance. The potentiodynamic polarization, electrochemical impedance spectroscopy (EIS) tests, and exposure experiments all show that the corrosion resistance of NiP-SiC coatings first increases and then decreases when the SiC content increases, but the corrosion resistance of NiP-SiC composite coating is better than that of amorphous NiP coatings.     

HOVF喷涂Ni–22Cr–10Al–1Y 和Ni–22Cr–10Al–1Y–SiC (N)涂层对ASTM-SA213-T22钢组织和热腐蚀行为的影响

The present paper deals with the investigation of microstructure and high-temperature hot corrosion behavior of high-velocity oxy fuel (HVOF)-produced coatings. Two powder coating compositions, namely, Ni22Cr10Al1Y alloy powder and Ni22Cr10Al1Y (80wt%; micro-sized)–silicon carbide (SiC) (20wt%; nano (N)) powder, were deposited on a T-22 boiler tube steel. The hot corrosion behavior of bare and coated steels was tested at 900°C for 50 cycles in Na₂SO₄–60wt%V₂O₅ molten-salt environment. The kinetics of corrosion was established with weight change measurements after each cycle. The microporosity and microhardness of the as-coated samples have been reported. The X-ray diffraction, field emission-scanning electron microscopy/energy dispersive spectroscopy, and X-ray mapping characterization techniques have been utilized for structural analysis of the as-coated and hot-corroded samples. The results showed that both coatings were deposited with a porosity less than 2%. Both coated samples revealed the development of harder surfaces than the substrate. During hot corrosion testing, the bare T22 steel showed an accelerated corrosion in comparison with its coated counterparts. The HVOF-sprayed coatings were befitted effectively by maintaining their adherence during testing. The Ni22Cr10Al1Y–20wt%SiC (N) composite coating was more effective than the Ni–22Cr–10Al–1Y coating against corrosion in the high-temperature fluxing process.     

Electrochemical behavior of different shelled microcapsule composite copper coatings

Copper/liquid microcapsule composite coatings with polyvinyl alcohol (PVA), gelatin or methyl cellulose (MC) as shell materials were prepared by electrodeposition. The influence of shell materials on the corrosion resistance of the composite coatings in 0.1 M H₂SO₄ was investigated by means of electrochemical techniques, scanning electron microscopy (SEM), and energy dispersion spectrometry (EDS). The results show that the participation of microcapsules can enhance the corrosion resistance of the composite coatings compared with the traditional copper layer. Based on the analysis of electrochemical test results, the release ways of microcapsules were deduced. Gelatin and MC as the shell materials of microcapsules are easy to release quickly in the composite coating. On the contrary, the releasing speed of PVA microcapsules is relatively slow due to their characteristics.     

Effect of benzaldehyde on the electrodeposition and corrosion properties of Ni–W alloys

The effect of different concentrations of benzaldehyde on the electrodeposition of Ni–W alloy coatings on a mild steel substrate from a citrate electrolyte was investigated in this study. The electrolytic alkaline bath (pH 8.0) contained stoichiometric amounts of nickel sulfate, sodium tungstate, and trisodium citrate as precursors. The corrosion resistance of the Ni–W-alloy-coated specimens in 0.2 mol/L H₂SO₄ was studied using various electrochemical techniques. Tafel polarization studies reveal that the alloy coatings obtained from the bath containing 50 ppm benzaldehyde exhibit a protection efficiency of 95.33%. The corrosion rate also decreases by 21.5 times compared with that of the blank. A higher charge-transfer resistance of 1159.40 Ω·cm2 and a lower double-layer capacitance of 29.4 μF·cm-2 further confirm the better corrosion resistance of the alloy coating. X-ray diffraction studies reveal that the deposits on the mild steel surface are consisted of nanocrystals. A lower surface roughness value (R_max) of the deposits is confirmed by atomic force microscopy.     

Corrosion behaviors of zinc and Zn-Ni alloy compositionally modulated multilayer coatings

Zinc and Zn-Ni alloy compositionally modulated multilayer (CMM) coatings were electrodeposited from dual baths. The coated samples were evaluated in terms of surface appearance, surface and cross-sectional morphologies, as well as corrosion resistance. The results obtained from the salt spray test show that the zinc and Zn-Ni alloy CMM coatings are more corrosion-resistant than the monolithic coatings of zinc or Zn-Ni alloy alone with a similar thickness. The corrosion potential measurement and anodic polarisation tests were undertaken to examine the probable corrosion mechanisms of zinc and Zn-Ni alloy CMM coatings. Analysis on the micrographic features of zinc and Zn-Ni alloy CMM coatings after the corrosion test explains the probable reasons why the Zn-Ni/Zn CMM coatings have a better protective performance. Surface morphologies and compositional analysis of the remaining coating material of Zn-Ni alloy deposit after the corrosion test confirms the dezincification mechanism of the Zn-Ni alloy deposit during the corrosion process.     

Corrosion behavior of aluminum alloys in Na2SO4 solution using the scanning electrochemical microscopy technique

The corrosion behavior of aluminum alloys 1060 and 2A12 in a 10 mM Na₂SO₄+5 mM KI solution was investigated by scanning electrochemical microscopy (SECM) and scanning electron microscopy (SEM). The potential topography and corrosion morphology results show that the potential of the sample surface over the same area changes with the increase of immersion time. The corrosion area becomes large, and the potential becomes more negative. The corrosion potential of the 2A12 alloy surface is lower than that of 1060 aluminum, and 2A12 alloy becomes easily corrosive. This is the reason that preferential dissolution in the boundary region of some intermetallic particles (IMPs) occurs and different dissolution behaviors are associated with different types of IMPs because of different potentials.     

Effect of intermetallic phases on the anodic oxidation and corrosion of 5A06 aluminum alloy

Intermetallic phases were found to influence the anodic oxidation and corrosion behavior of 5A06 aluminum alloy. Scattered intermetallic particles were examined by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) after pretreatment. The anodic film was investigated by transmission electron microscopy (TEM), and its corrosion resistance was analyzed by electrochemical impedance spectroscopy (EIS) and Tafel polarization in NaCl solution. The results show that the size of Al-Fe-Mg-Mn particles gradually decreases with the iron content. During anodizing, these intermetallic particles are gradually dissolved, leading to the complex porosity in the anodic film beneath the particles. After anodizing, the residual particles are mainly silicon-containing phases, which are embedded in the anodic film. Electrochemical measurements indicate that the porous anodic film layer is easily penetrated, and the barrier plays a dominant role in the overall protection. Meanwhile, self-healing behavior is observed during the long immersion time.     

The enhanced corrosion resistance of UMAO coatings on Mg by silane treatment

The surface silanization was carried out on ultrasonic micro-arc oxidation(UMAO) coatings on pure magnesium using KH550 as silane coupling agent(SCA). The surface morphology, chemical bonds and corrosion resistance of the silane films were investigated by scanning electron microscope(SEM), Fourier transform infrared spectroscopy(FTIR) and electrochemical workstation, respectively. The results showed that hybrid coatings were successfully prepared on pure magnesium by UMAO-Na OH(1 mol/L, 2 mol/L, 3 mol/L)-SCA processing. The organic films with Si–O–Mg bonds are helpful for the reduction of the pores in UMAO coatings. The pores decreased with increasing Na OH concentration. Compared with single UMAO treatment, the corrosion potentials(Ecorr) of magnesium plates with UMAO-Na OH(1 mol/L,2 mol/L, 3 mol/L)-SCA treatment increased by 29 m V, 53 m V and 75 m V, respectively, meanwhile the corrosion current density(Icorr) reduced one to two orders of magnitude. It indicated that the corrosion resistance of the coatings was improved by silane treatment.     

Corrosion behavior and corrosion products of a low-alloy weathering steel in Qingdao and Wanning

A newly developed low-alloy weathering steel has been exposed in two coastal sites (Qingdao in the north, Wanning in the south) in China for one year. The samples in Wanning corroded far more seriously than those in Qingdao. The rust layer formed on the steel was analyzed by X-ray diffraction (XRD), scanning electron microscopy (SEM), N₂ adsorption approach, polarization curves, and electrochemical impedance spectroscopy (EIS). The rust formed in Qingdao contains more X-ray amorphous compounds and is more compact than that formed in Wanning. Cr and Cu are enriched in the rust layer near the steel matrix, and the phenomenon is more obvious in Qingdao than in Wanning. The rust layer formed in Qingdao suppresses the anodic and cathodic reaction more remarkably than that formed in Wanning does. The rust layer formed in Qingdao possesses a higher ability to block the permeation of chloride ions than that formed in Wanning does.     

Preparing Ca-P coating on biodegradable magnesium alloy by hydrothermal method: In vitro degradation behavior

Magnesium alloys are potentially attractive biodegradable materials.However,their rapid corrosion rate limits their biomedical application.To slow down the rate of biodegradation,a protective calcium-phosphate coating was formed on a magnesium alloy substrate by a hydrothermal method.Scanning electron microscope results showed that the coating consisted of two layers with different crystalline characteristics.The loose outer layer showed a prism-like crystal structure,while the compact inner layer is a dense ultra-fine regular di-pyramid-like structure with an average grain dimension of ～200 nm.The compositions of the inner layer and outer layer were calcium-deficient hydroxyapatite (Ca-def HA) and dicalcium phosphate (DCPa),respectively.The coating adhered well to the substrate with a thickness of about 15 m.Immersion in Hank’s solution indicated that the coating could significantly improve the degradation properties of magnesium alloy.The pH of the solution containing the coated samples increased much more slowly than the untreated control.After 8 d immersion,the uncoated sample had corroded seriously while the coated sample was much less corroded.The Ca/P atom ratio in both the layers of the coating increased and the coating was still protecting the substrate.The two layers of the coating corroded differently because of differences in solubility.The outer layer was more severely attacked and many holes were formed on the surface,the inner layer suffered less attack.In addition,a growth of precipitate on the inner layer was observed,indicating that surface bioactivity was improved by the coating.Thus,magnesium alloys coated with a Ca-P coating prepared by a hydrothermal method are promising candidate biodegradable biomaterials,and further investigation of in vivo degradation behavior is suggested.     

Preparation and characterization of a chitosan-based low-pH-sensitive intelligent corrosion inhibitor

A chitosan (CS)-based low-pH-sensitive intelligent corrosion inhibitor was prepared by loading a pH-sensitive hydrogel with benzotriazole (BTA); the pH-sensitive hydrogel was synthetized by crosslinking CS with glutaraldehyde (GTA). Analysis by Fourier- transform infrared (FT–IR) spectroscopy showed that Schiff reactions occurred between amino and aldehyde groups. The swelling ability of the hydrogel was investigated using a mass method, and it was observed to swell more in an acidic environment than in an alkaline environment. The hydrogel’s loading capacity of BTA was approximately 0.377 g·g-1, and its release speed was faster in an acidic environment than in an alkaline environment because of its swelling behavior. The corrosion inhibition ability of the intelligent inhibitor was tested by immersion and electrochemical methods. The results showed that after 4 h of immersion, the polarization resistance (R4) value of copper with the intelligent inhibitor was approximately twice of that of copper with BTA, indicating that the intelligent inhibitor could effectively prevent copper from corroding.