The effect of copper additives on hybrid Zr-based chemical conversion coating morphology and chemical compositions

IF 7.5 Q1 CHEMISTRY, PHYSICAL

Applied Surface Science Advances Pub Date : 2025-03-26 DOI:10.1016/j.apsadv.2025.100726

Ankita Mohanty , Xiaoyang Liu , Cheng-Chu Chung , Donald Vonk , Kim Kisslinger , Xiao Tong , Andrew Kiss , Gary Halada , Stanislas Petrash , Kate Foster , Yu-chen Karen Chen-Wiegart

{"title":"The effect of copper additives on hybrid Zr-based chemical conversion coating morphology and chemical compositions","authors":"Ankita Mohanty , Xiaoyang Liu , Cheng-Chu Chung , Donald Vonk , Kim Kisslinger , Xiao Tong , Andrew Kiss , Gary Halada , Stanislas Petrash , Kate Foster , Yu-chen Karen Chen-Wiegart","doi":"10.1016/j.apsadv.2025.100726","DOIUrl":null,"url":null,"abstract":"<div><div>In the realm of corrosion protection, Zr-based conversion coatings offer an environmentally friendly, chromate-free alternative to conventional coating. This study uses advanced X-ray, electron microscopy and electrochemical testing techniques to better understand the impact of varying Cu²⁺ ion concentrations on the characteristics of Zr-based coatings on Fe substrates. Our findings demonstrate that within the tested conditions, higher Cu²⁺ additive concentrations at 40 ppm enhance surface characteristics, increasing stability towards anti-corrosion capability, particularly under NaCl treatment. Conversely, at a lower Cu²⁺ concentration of 20 ppm, coatings exhibited more significant dissolution of Cu clusters and increased vulnerability to chloride-induced degradation. X-ray photoelectron spectroscopy and synchrotron X-ray fluorescence (XRF) and X-ray absorption near edge structure (XANES) spectroscopy analyses revealed Cu²⁺ formation in Cu20, while Cu40 retained its metallic state (Cu⁰) with a slower reaction rate. Cu20 offers some protection but lacks durability, whereas in Cu40, lower I<sub>corr</sub>, and enhance corrosion resistance, making it ideal for protective coatings in salt-water environments. This study underscores the importance of balancing Cu²⁺ ions concentration in the coating solution to optimize performance, highlighting the role of Cu in enhancing both surface properties and long-term stability.</div></div>","PeriodicalId":34303,"journal":{"name":"Applied Surface Science Advances","volume":"27 ","pages":"Article 100726"},"PeriodicalIF":7.5000,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Applied Surface Science Advances","FirstCategoryId":"1085","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2666523925000340","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"CHEMISTRY, PHYSICAL","Score":null,"Total":0}

引用次数: 0

Abstract

In the realm of corrosion protection, Zr-based conversion coatings offer an environmentally friendly, chromate-free alternative to conventional coating. This study uses advanced X-ray, electron microscopy and electrochemical testing techniques to better understand the impact of varying Cu²⁺ ion concentrations on the characteristics of Zr-based coatings on Fe substrates. Our findings demonstrate that within the tested conditions, higher Cu²⁺ additive concentrations at 40 ppm enhance surface characteristics, increasing stability towards anti-corrosion capability, particularly under NaCl treatment. Conversely, at a lower Cu²⁺ concentration of 20 ppm, coatings exhibited more significant dissolution of Cu clusters and increased vulnerability to chloride-induced degradation. X-ray photoelectron spectroscopy and synchrotron X-ray fluorescence (XRF) and X-ray absorption near edge structure (XANES) spectroscopy analyses revealed Cu²⁺ formation in Cu20, while Cu40 retained its metallic state (Cu⁰) with a slower reaction rate. Cu20 offers some protection but lacks durability, whereas in Cu40, lower I_corr, and enhance corrosion resistance, making it ideal for protective coatings in salt-water environments. This study underscores the importance of balancing Cu²⁺ ions concentration in the coating solution to optimize performance, highlighting the role of Cu in enhancing both surface properties and long-term stability.

Abstract Image

查看原文本刊更多论文

在防腐蚀领域，Zr 基转化涂层提供了一种不含铬酸盐的环保型传统涂层替代品。本研究采用先进的 X 射线、电子显微镜和电化学测试技术，以更好地了解不同 Cu²⁺ 离子浓度对铁基底上 Zr 基涂层特性的影响。我们的研究结果表明，在测试条件下，Cu²⁺添加剂浓度越高（40 ppm），表面特性越好，抗腐蚀能力稳定性越强，尤其是在氯化钠处理条件下。相反，在较低的 Cu²⁺ 浓度（20 ppm）下，涂层表现出更明显的铜簇溶解，更容易受到氯化物引起的降解的影响。X 射线光电子能谱和同步辐射 X 射线荧光 (XRF) 以及 X 射线吸收近边缘结构 (XANES) 光谱分析显示，Cu20 中形成了 Cu²⁺，而 Cu40 则保持了金属状态（Cu⁰），但反应速度较慢。Cu20 具有一定的保护作用，但缺乏耐久性，而 Cu40 的 Icorr 较低，耐腐蚀性较强，是盐水环境中理想的保护涂层。这项研究强调了平衡涂层溶液中 Cu²⁺ 离子浓度以优化性能的重要性，突出了 Cu 在增强表面性能和长期稳定性方面的作用。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊