Environmentally
friendly chromate-free, zirconium (Zr)-based conversion
coating is a promising green technology for corrosion protection.
Additives in the surface treatment provide critical functionalities
and performance improvements; however, mechanistic understanding as
to how the additives influence the coatings remains unclear. In this
study, a new organic–inorganic hybrid Zr-based conversion coating
combines copper (Cu) compounds and polyamidoamine (PAMAM), taking
advantage of the complementary nature of organic and inorganic additives.
A multimodal approach combining electron and X-ray characterization
is applied to study the interaction of Cu2+ and PAMAM and
the resulting impacts on coating formation. Adding PAMAM changed the
surface morphology, thickness, distribution of Cu in the clusters,
and void formation of the coatings. High PAMAM (100–200 ppm)
leads to little conversion coating formation, and low PAMAM (0–25
ppm) shows voids formation under the coatings. Moreover, PAMAM incorporates
in the coating in the form of a PAMAM–Cu complex with a higher
concentration toward the surface, providing an organic layer at the
surface of the coating. X-ray absorption near-edge structure (XANES)
spectroscopy shows the difference between the conventional and the
hybrid coating treatments in an alkaline solution to simulate the
E-coat process, suggesting the contribution of PAMAM in the enhanced
chemical stability in an alkaline environment. Therefore, an intermediate
range of addition of PAMAM (50 ppm) is optimal to (1) avoid excessive
voids formation, (2) promote some Cu cluster formation and thus enhance
the Zr-based coating formation, and (3) incorporate organic components
into the coating to improve the adhesion of the subsequent coatings.
Overall, this work furthers our knowledge on the formation mechanism
of an effective and environmentally friendly hybrid conversion coating
for corrosion inhibition, demonstrating a critical processing–structure–property
relationship. This study will benefit future development of green
and effective surface treatment technology.