Hybrid coatings based on Si and Zr were assessed for their protection of aluminum and its alloys 2024-T3 and 7075-T6 against corrosion in 0.5 M NaCl. Coatings were prepared from sol synthesized from mixtures of tetraethyl orthosilicate and 3-methacryloxypropyl trimethoxysilane to which various concentrations of zirconium tetrapropoxide and methacrylic acid were added. Short-and long-term electrochemical behavior was assessed. The degree of protection was dependent on the sol composition, ageing time and curing temperature. A coating containing Zr/Si ratio of 0.41, aged for 48 h and cured at 100 • C exhibited the best combination of resistance towards general and localized corrosion. Electrochemical parameters obtained under polarization (corrosion current density of 4.4 nA/cm 2 and stability up to 7 V), and under open circuit conditions (impedance in the few tens of Mohm cm 2 after one week immersion) prove that the protection was high. At other conditions, such as higher Zr/Si ratios, shorter ageing time or curing at room temperature, protection was excellent early after immersion but then lessened rapidly. Coatings prepared under optimal conditions provided a high degree of protection over 500 hours salt spray testing, especially on aluminum metal. These coatings have the potential to provide good protection in chloride environments. While aluminum has good corrosion resistance in seawater, its high-strength alloys in the 2xxx (Al-Cu-Mg) and 7xxx series (Al-ZnMg) are normally not recommended for use under these conditions.
1,2Since there is an ongoing need for light-weight, high-strength materials, the possibility of using alloys other than those of the series 5xxx (Al-Mg-Mn) and 6xxx (Al-Mg-Si) normally recommended for sea-coast applications has to be considered.
2,3Aluminum and its alloys are highly susceptible to oxidation, resulting in the passivation of the surface by a 0.01 to 10 μm thick oxide layer when exposed to air. This naturally formed oxide protects aluminum under atmospheric conditions.2 Passivation of the alloys is, however, less effective. Due to the presence of unevenly distributed intermetallic particles (IMPs), the passive film is, overall, thinner and less uniform. IMPs such as Al 2 CuMg, Al-Cu-Mn-Fe, Al 2 Cu, Al 3 Fe, MgSi 2 , MgZn 2 , create local galvanic cells that promote corrosion on the surface. [4][5][6] Al 2 O 3 is a good insulator but, when containing IMPs, is a semiconductor that allows limited passage of electrons.2 High concentrations of chloride ions allows localized breakdown of the aluminum oxide film, most commonly observed as pitting, crevice or galvanic corrosion.Al alloys have been protected for decades using chromate conversion coatings. In the last decade these coatings have been widely prohibited within 7 and outside 8 the EU due to the fact that hexavalent chromium is a toxic, carcinogenic and environmentally hazardous compound.9-11 Other environmentally hazardous compounds, such as volatile organic compounds (VOCs) used, for example, in the painting industry, have ...