Investigation of the corrosion behaviour of a bilayer cerium-silane pre-treatment on Al 2024-T3 in 0.1M NaCl

Construction of novel polybenzoxazine coating precursor exhibiting excellent anti-corrosion performance through monomer design

In this study, we utilized salicylaldehyde (SA) and p-toluidine (Tol-NH₂) to synthesize 2-(Z)[(4-methylphenyl)imino]methylphenol (SA-Tol-SF), which was then reduced to 2-[(4-methylphenyl)amino]methylphenol, producing SA-Tol-NH. SA-Tol-NH was further reacted with formaldehyde to create SA-Tol-BZ monomer. Poly(SA-Tol-BZ) was produced by thermally curing it at 210 °C, after synthesizing it from SA-Tol-BZ. The chemical structure of SA-Tol-BZ was analyzed using various analytical techniques such as FT-IR, ¹H NMR spectroscopy, and ¹³C NMR spectroscopy TGA, SEM, DSC, and X-ray analyses. Afterward, we applied the obtained poly(SA-Tol-BZ) onto mild steel (MS) using thermal curing and spray coating techniques. To examine the anticorrosion attributes of MS coated with poly(SA-Tol-BZ), electrochemical characterization was employed. The study proved that poly(SA-Tol-BZ) coating had a high level of effectiveness in preventing corrosion on MS, with an efficacy of 96.52%, and also exhibited hydrophobic properties.

Evolution and stability of 2-mercaptobenzimidazole inhibitor film upon Al alloy 6061

Organic corrosion inhibitors have become competent alternatives to hazardous chrome conversion coatings due to their rapid adsorption over metal surfaces in corrosive environments. Literature suggests a wide range of organic corrosion inhibitors with high inhibition efficiency, barrier properties, and adsorption mechanisms. However, the long-term durability and protectiveness of an organic inhibitor film need to be understood with in-depth insights on its interaction with heterogenous alloy surfaces like AA6xxx, reduction of galvanic activities and time-resolved degradation due to ionic diffusion. The present article is focused on the time-resolved adsorption and degradation of 2-mercaptobenzimidazole (2-MBI)-induced inhibitor layer/film over AA6061 in 0.1 M NaCl solution. Electrochemical and surface analysis data indicate that the presence of 2-MBI drives the rapid formation of a 20–30 nm thick protective film comprised of constitutional elements of C, S, and N from 2-MBI upon the surface of AA6061 substrate. This film mitigated the corrosion cells associated with nano- and micro-sized Fe and Si-rich intermetallic particles (IMPs) in AA6061. XPS reveals two distinguished bonding states of S and N in the inhibitor film and chemical interactions between 2-MBI and the surface of AA6061. The protective film maintained 65% inhibiting efficiency after 1 day, which progressively degraded due to electrolyte ingress and eventually with a drop in inhibition efficiency down to 21% after 14 days. Inhibitor-induced film over AA6061 reduced the corrosion susceptibility of Fe, and Si-rich IMPs up to 1 day given the subsequent adsorption by S and N heteroatoms. However, this film became thick and defective after 1 day, which undermined its barrier properties against ingress of aggressive ions and facilitated water adsorption.

Graphical abstract

Superhydrophobic Films with Enhanced Corrosion Resistance and Self-Cleaning Performance on an Al Alloy

In this article, a novel and facile method is used to construct superhydrophobic surfaces on aluminum alloys. A solution of aluminum chloride hexahydrate and N-dodecyltrimethoxysilane (DTMS) in ethanol was used as the electrolyte solution. The hydrolysis of DTMS was accelerated during the electrodeposition process, and the hydrolysate was bonded to a pretreated aluminum surface. The prepared aluminum alloy sample exhibits both superhydrophobicity (the surface water contact angle reached 155°) and excellent corrosion resistance. The inhibition efficiency of this sample is as high as 99.9% in 3.5 wt % NaCl solution, which remains at 98% even after 30 days of immersion. Thus, our fabrication can be well applied to the field of marine corrosion protection. Therefore, the working mechanism was discussed by confocal Raman microspectroscopy (CRM). In addition, the investigation by CRM and electrochemical impedance spectroscopy (EIS) also indicates that superhydrophobic samples show good stability in NaCl solution. The fabrication method can inspire new ideas for the construction of superhydrophobic aluminum alloys in the marine environment.

Evaluation of biodegradable Zn-1%Mg and Zn-1%Mg-0.5%Ca alloys for biomedical applications

Increasing interest in biodegradable metals (Mg, Fe, and Zn) as structural materials for orthopedic and cardiovascular applications mainly relates to their promising biocompatibility, mechanical properties and ability to self-remove. However, Mg alloys suffer from excessive corrosion rates associated with premature loss of mechanical integrity and gas embolism risks. Fe based alloys produce voluminous corrosion products that have a detrimental effect on neighboring cells and extracellular matrix. In contrast, Zn does not appear to exhibit a harmful mode of corrosion. Unfortunately, pure zinc possesses insufficient mechanical strength for biomedical structural applications. The present study aimed at examining the potential of two new zinc based alloys, Zn-1%Mg and Zn-1%Mg-0.5%Ca to serve as structural materials for biodegradable implants. This examination was carried out under in vitro conditions, including immersion testing, potentiodynamic polarization analysis, electrochemical impedance spectroscopy (EIS), and stress corrosion cracking (SCC) assessments in terms of slow strain rate testing (SSRT). In order to assess the cytotoxicity of the tested alloys, cell viability was evaluated indirectly using Saos-2 cells. The results demonstrate that both zinc alloys can be considered as potential candidates for biodegradable implants, with a relative advantage to the Zn-1%Mg alloy in terms of its corrosion resistance and SCC performance.

Corrosion protection of hydrophobic bisphenol A-based polybenzoxazine coatings on mild steel

Hydrophobic bisphenol A-based polybenzoxazine coatings with excellent corrosion resistance were prepared through a simple dip coating and thermal curing method.