Search Results (73)

The initial reactivity of a multiphase ZnAlMgSi coating with an Al content > 30 wt.% was studied by in situ reflective microscopy under alternating applied potentials +50 mV/−50 mV vs. open-circuit potential in 5 wt.% NaCl and 5 wt.% Na₂SO₄ aqueous solutions. In both environments, galvanic coupling between different coating phases and the anodic behavior decreased in the order binary ZnAl > binary Zn/Zn₂Mg > Zn₂Mg > Al(Zn); dendrites were evidenced for the coating exposed alone as well as in galvanic coupling with steel. Contrary to the observations known for Zn-rich ZnAlMg coatings, pure Zn₂Mg was less reactive than the pure ZnAl phase, underlining the importance of the microstructure for reactivity. Si-needles were systematically cathodic, and Al(Zn) dendrites have shown cathodic behavior in some couplings. In the configuration of coupling with steel, corrosion started at the interfaces “binary ZnAl/steel substrate” or “binary ZnAl/Si particle”. The distribution and nature of the corrosion products formed during the experiment were assessed using X-ray microanalysis in scanning electron microscopy and confocal Raman microscopy. In the sulfate environment, a homogenous and stable corrosion product layer formed from the first steps of the degradation; this was in contrast to the chloride environment, where no surface film formed on the dendrites. Full article

Plasma electrolytic oxidation (PEO) is an advanced electrochemical surface treatment technology. It can effectively improve the corrosion resistance of magnesium and its alloys. This paper aims to form protective PEO coatings on an AZ31 substrate with different electrolytes, while monitoring the micro-discharge evolution by noise intensity and morphology analysis. By setting the PEO parameters and monitoring process characteristics, such as current density, spark appearance, and noise intensity, it was deduced that the PEO process consists of the following three stages: anodic oxidation, spark discharge, and micro-arc discharge. The PEO oxide coating formed on the AZ31 alloy exhibits various irregular volcano-like structures. Oxygen species are uniformly distributed along the coating cross-section. Phosphorus species tend to be enriched inwards to the coating/magnesium substrate interface, while aluminum piles up towards the surface region. Surface roughness of the PEO coating formed in the silicate-based electrolyte was the lowest in an arithmetic average height (Sa) of 0.76 μm. Electrochemical analysis indicated that the corrosion current density of the PEO coating decreased by about two orders of magnitude compared to that of untreated blank AZ31 substrate, while, at the same time, the open-circuit potential shifted significantly to the positive direction. The corrosion current density of the 10 min/400 V coating was 1.415 × 10⁻⁶ A/cm², approximately 17% lower than that of the 2 min/400 V coating (1.738 × 10⁻⁶ A/cm²). For a fixed 10 min treatment, the longer the PEO duration time, the lower the corrosion current density. Finally, the tested potentiodynamic polarization curve reveals the impact of different types of PEO electrolytes and different durations of PEO treatment on the corrosion resistance of the oxide coating surface. Full article

Magnesium alloys are widely used in all kinds of fields because of their excellent mechanical properties, but their application has been prevented by poor corrosion resistance. In this paper, Mg(OH)₂-Ca(OH)₂/Al(OH)₃/Al₂O₃ composite coatings with long-term corrosion resistance were fabricated on the surface of Mg alloys using the hydrothermal method. Among them, the calcium hydroxide/calcium nitrate–alumina coating successfully filled the cracks in the magnesium hydroxide coating. Meanwhile, we explored the influences of different heating times and temperatures on the coating and analyzed its composition. After immersing the coating in a 3.5% NaCl solution for 168 h, only a small portion of the surface dissolved. Electrochemical test results indicated that the corrosion potential and corrosion current density of the coating increased by three orders of magnitude, significantly improving corrosion resistance in comparison to bare samples. Adhesion tests showed that the coating exhibited good bonding performance to the substrate. This method features a simple, pollution-free preparation process and does not require complex instrumentation, thereby enhancing the longevity of the magnesium alloy. Full article

The surface of AM60 magnesium alloy was modified with Al-nanocoating ~65.62 nm, using DC magnetron sputtering to enhance its resistance to degradation under aggressive marine ambience. The sputtered Al film showed adhesion to the α-Mg matrix, covering the dispersed particles of the β-Mg₁₇Al₁₂ secondary phase. The aluminum nanofilm was composed of (111) and (200) crystal planes of metallic aluminum (Al⁰) and Al₂O₃ (Al³⁺). After 30 days of immersion in a simulated marine environment (SME, pH 7.8), the Al-AM60 maintained a lower alkaline value (pH~8.13) of SME than that of uncoated AM60, attributed to α-Mg electrochemical oxidation to Al₂O₃ and its posterior dissolution, consuming OH⁻ ions. Consequently, the concentration of the released Mg²⁺ ions from the Al-AM60 surface was reduced ~2.3 times (~15 mg L⁻¹). The Rp (polarization resistance), as inversely proportional to the corrosion current, was extracted from the EIS impedance data fitted to an equivalent electrical circuit. After 30 days in SME solution, the Rp value of the Al-AM60 modified surface was ~3.5 times higher than that of AM60 (~15.46 kΩ cm²), confirming that the sputtered aluminum nano-deposit layer can hinder the corrosion process. These reported findings indicated that sputtered Al nano-coatings can mitigate the surface degradation of Mg-Al alloys in saline aggressive marine environments. Full article

Plasma electrolytic oxidation (PEO) is an electrochemical surface modification technique for producing dense oxide layers on valve metals. This review compiles the various modifications to the PEO process that have been used to improve the produced coatings and make them suitable for specific applications, with a focus on examples of aluminum, magnesium, and titanium substrates. An overview of the PEO process is given, highlighting the various process parameters and their effects on the final surface. The challenges with light metals that motivate the use of surface modifications are summarized, along with some of the other modifications that attempt to overcome them. Two broad categories of modifications to the PEO process are presented: in situ modifications, influencing the properties of the coating during its formation, and ex situ modifications, augmenting the properties of an already-formed coating. Finally, specific examples of applications for modified PEO processes are discussed, including battery, biomedical, water treatment, and energy production applications. Full article

Defluoridation of water was investigated in an adsorption column study using Al-Mg-Ca-coated sand (AMCCS), a ternary metal oxide adsorbent with eco-friendly components that were shown to be effective for water defluoridation, in a batch adsorption study. A packed column of the AMCCS sorbent was evaluated as function of column flow rate, solution type, and sorbent recyclability. Adsorption column experiments included two column flow rates of 2 mL/min and 10 mL/min using two different solutions: deionized water and a synthetic solution representative of groundwater. Greater fluoride column adsorption capacity was obtained at the lower flow rate for both solutions, mainly due to longer contact times between solution and AMCCS sorbent. Adsorption of fluoride occurred through physical adsorption, which followed the Langmuir adsorption model and second-order kinetics for deionized water and synthetic solution. A lower AMCCS column fluoride adsorption capacity was observed for the synthetic solution due to the competition from adsorption of other ions in the synthetic solution, whereas fluoride adsorption by the AMCCS column was influenced by interphase mass transfer to a lesser extent using the synthetic solution than deionized water. The re-coating of spent AMCCS sorbent in the adsorption column resulted in effective recycling and reuse of the AMCCS adsorption column for both deionized water and the synthetic solution, rendering the AMCCS adsorption column a recyclable and sustainable flow through water defluoridation system. Full article

A new combined analysis of SEM-BSE and EDX images using Aphelion^TM software was proposed to describe the quantitative microstructure (quantity and neighborhood of sacrificial phases) of Al-Zn-Si-(Mg) coatings on steel. Three materials with different Al/Zn ratios and Mg content were analyzed. The quantitative microstructure allowed us to describe their corrosion behaviors in a chloride environment and understand their ranking for sacrificial protection of steel in accelerated corrosion tests. For the analyses, interdendritic Zn-rich or Mg-rich phases were expected to be more sacrificial to steel than Al-rich dendrites. Without Mg (AZ coating), Al-rich dendrites created a percolating network, but interdendritic phases did not, suggesting their sacrificial protection to steel to be very limited. Additionally, significant Zn gradients inside dendrites led to a premature coating consumption on the surface, creating new zones of naked steel. In the coatings with Mg (AZM), sacrificial interdendritic phases created a percolating network, which is expected to improve long-time sacrificial protection and contribute to a more uniform formation of Zn corrosion products. For Al content between 30 wt.% and 45 wt.%, a lowering of the Al/Zn ratio (L-AZM) increased the connectivity of the sacrificial interdendritic phases, which is expected to improve the long-term sacrificial effect. Accelerated corrosion tests of scratches in the steel coatings validated the hypotheses. Full article

Magnesium-based alloys are considered to be promising materials for the fabrication of temporary bone repair medical implants. The AZ31 magnesium-based (AZ31-Mg) alloy contains 3% aluminum and 1% zinc in its microstructure, which gives it mechanical strength and corrosion resistance. Nonetheless, the corrosion rate is high, which can lead to implant failure due to rapid degradation, which triggers the release of harmful metal ions. In the present work, a passive layer was obtained on the AZ31-Mg alloy, and subsequently, a cerium oxide (CeO₂) coating was deposited through a chemical conversion treatment using 0.01 M CeO₂ as a precursor. Based on X-ray photoelectron spectroscopy, the calculated amount of Ce(IV) and Ce(III) present in AZ31-Mg(OH)₂/CeO₂ was 93.6% and 6.4%, respectively. AZ31-Mg(OH)₂/CeO₂ showed improved corrosion resistance compared with the bare sample. The in vitro assessment of MC3T3-E1 pre-osteoblast cell viability showed that AZ31-Mg(OH)₂/CeO₂ was biocompatible after incubation for 24 and 72 h. The results revealed that the CeO₂ coating confers greater electrochemical stability and biocompatibility properties, mostly due to the presence of Ce⁴⁺ ions. Full article

Aluminum solid-state batteries are emerging as one of the most promising energy storage systems, offering advantages such as low cost and high safety. This study adopts a safe and cost-effective approach by alloying and doping the all-solid-state aluminum-ion battery to enhance its electrochemical performance. This research further explores the electrochemical impacts of these modifications on the performance of solid-state aluminum batteries. In this experiment, aluminum-based anodes were deposited onto nickel foil using the thermal evaporation (TE) method. At the same time, the graphite film (GF) cathode material was enriched with sodium (GFN) through a solution-based process. The system was combined with magnesium silicate solid electrolytes to investigate the all-solid-state aluminum-carbon battery′s structural characteristics and charge–discharge mechanisms. The experimental results demonstrate that the aluminum-coated electrode alloying effects and the graphite film modification significantly improve battery performance. The system achieved a maximum specific capacity of approximately 700 mAh g⁻¹, with a cycle life exceeding 100 cycles. Furthermore, the microstructural characteristics and phase structure of the aluminum evaporation film were confirmed. Analysis of ion transport pathways during the charge–discharge cycles of the all-solid-state aluminum-carbon battery revealed that both aluminum and magnesium ions play critical roles in the electrode processes. Full article

The current electrolytes used for metal electrodeposition mostly use aqueous solutions that limit the range and quality of possible coatings. Also, some of these solutions may contain toxic and corrosive chemicals. Thus, the importance of ionic liquids (ILs) and deep eutectic solvents (DES) becomes clear, as they can be used as green non-aqueous electrolytes for the electrodeposition of a range of reactive metals that are impossible to deposit in aqueous solutions and for the improved electrodeposition of metals that are deposable in aqueous solutions. This paper presents some examples of electrodeposition in ILs and DESs that are considered specific processes. Aluminum, as an active metal that it is impossible to electrodeposit in aqueous solution, was electrodeposited from a chloroaluminate IL. Moreover, the electrodeposition of Al was carried out in open air using a novel approach. Chromium was electrodeposited from a DES containing the environmentally friendly form of Cr (III) instead of toxic Cr (VI). Magnesium alloys, as water-sensitive substrates, were electroplated in an air and water-stable DES. Also, this paper discloses, for the first time, the procedure of pretreatment of Mg alloys for successful electroplating. Full article

A self-lubricating coating is a kind of coating formed on the surface of the material by various processes that can self-replenish lubricating substances during the friction and wear process. This paper presents a comprehensive review of the processes and properties of self-lubricating ceramic coatings developed through Micro-arc Oxidation (MAO) on light alloys, including aluminum, magnesium, and titanium. Three technical approaches for the preparation of self-lubricating coatings via MAO are recapitulated. The structures and properties of the self-lubricating coatings prepared by each technical route are compared and analyzed, and the future development tendency of this field is also anticipated. Full article

Electroless ZnO (≈900 nm) was deposited on the surface of an Mg-Al alloy (AM60) to reduce its degradation in the marine environment. Uncoated and coated ZnO samples were exposed to an SME simulated marine solution for up to 30 days. The AFM and optical images revealed that the corrosion attack on the ZnO-AM60 surface was reduced due to an increase in the surface hydrophobicity of the ZnO coating (contact angle of ≈91.6°). The change in pH to more alkaline values over time was less pronounced for ZnO-AM60 (by ≈13%), whereas the release of ${\mathrm{Mg}}^{2+}$ ions was reduced by 34 times, attributed to the decrease in active sites on the Mg-matrix provided by the electroless ZnO coating. The OCP (free corrosion potential) of ZnO-AM60 shifted towards less negative values of ≈100 mV, indicating that electroless ZnO may serve as a good barrier for AM60 in a marine environment. The calculated polarization resistance (${\mathrm{R}}_{\mathrm{p}}$), based on EIS data, was ≈3 times greater for ZnO-AM60 than that of the uncoated substrate. Full article

To improve the wear and corrosion resistance, Al-Ni coating was prepared on Mg alloy by laser cladding, and the influence of the laser scanning speed on the microstructure, wear and corrosion resistance of the coatings was systematically analyzed. The results showed that the coatings with different scanning speeds were composed of Al₃Ni₂, Mg₁₇Al₁₂ and Mg₂Al₃ phases. The coatings presented fine needle-like grains. Under different scanning speeds, the microhardness of the coatings was 3.3–4.8 times that of the substrate, and the wear volume of the coatings was decreased by 40.08–51.38%. The coating with a laser scanning speed of 600 mm/min had the highest hardness, the best wear and corrosion resistance. Full article

This study focuses on the development of high-performance insulation materials to address the critical issue of reducing building energy consumption. Magnesium–aluminum layered double hydroxides (LDHs), known for their distinctive layered structure featuring positively charged brucite-like layers and an interlayer space, have been identified as promising candidates for insulation applications. Building upon previous research, which demonstrated the enhanced thermal insulation properties of methyl trimethoxysilane (MTS) functionalized LDHs synthesized through a one-step in situ hydrothermal method, this work delves into the systematic exploration of particle size regulation and its consequential effects on the thermal insulation performance of coatings. Our findings indicate a direct correlation between the dosage of MTS and the particle size of LDHs, with an optimal dosage of 4 wt% MTS yielding LDHs that exhibit a tightly interconnected hydrotalcite lamellar structure. This specific modification resulted in the most significant improvement in thermal insulation, achieving a temperature difference of approximately 25.5 °C. Furthermore, to gain a deeper understanding of the thermal insulation mechanism of MTS-modified LDHs, we conducted a thorough characterization of their UV-visible diffuse reflectance and thermal conductivity. This research contributes to the advancement of LDH-based materials for use in thermal insulation applications, offering a sustainable solution to energy conservation in the built environment. Full article

In this work, a novel zinc–aluminum–magnesium (Zn-Al-Mg, ZM) coated steel was prepared using the hot-dip method. The microstructure and corrosion resistance of the ZM-coated steel were investigated. Compared to the conventional galvanized steel (GI), the ZM coating demonstrated a distinctive phase structure, consisting of Zn phase, binary eutectic (Zn/MgZn₂), and ternary eutectic (Zn/Al/MgZn₂). The corrosion resistance of the ZM-coated and GI-coated steels was evaluated by neutral salt spray test (NSST), polarization and electrochemical impedance spectroscopy (EIS). The results indicated that ZM-coated steel provided superior long-term corrosion protection in a NaCl environment compared to GI-coated steel. The scanning vibrating electrode technique (SVET) proved to be an effective method for investigating the evolution of the anodic and cathodic on the local coating surface. GI-coated steel exhibited a potential and current density distribution between the cathodic and anodic sites nearly three orders of magnitude higher than that of ZM-coated steel, suggesting a higher corrosion rate for GI-coated steel. Full article