Poly(methyl methacrylate) intercalated layered double hydroxide film with enhanced alkaline corrosion resistance for aluminum alloy AA6061

Abstract

The oriented growth of Zn-Al LDH film perpendicular to the surface of AA6061 substrate was confirmed by scanning microscopy image and X-ray diffraction pattern. The LDH film achieved a complete surface coverage on the AA6061 substrate and exhibited strong corrosion resistance in NaOH solution (pH of 13). Furthermore, a preparation protocol for poly(methyl methacrylate) (PMMA)-LDH composite film was demonstrated. LDH film intercalated only with PMMA but not polyurethane demonstrated greatly enhanced alkaline corrosion resistance, showing a more positive corrosion potential and reduced corrosion current by four orders of magnitude in electrochemical polarization spectroscopy. The enhancement in corrosion resistance by PMMA intercalation could be attributed to the increasing compactness in the LDH film and increasing hydrophobicity.

This is a preview of subscription content, access via your institution.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

References

  1. 1.

    Metroke, TL, Parkhill, RL, Knobbe, ET, “Passivation of Metal Alloys Using Sol–Gel-Derived Materials—A Review.” Prog. Org. Coat., 41 (4) 233–238 (2001)

    CAS  Article  Google Scholar 

  2. 2.

    Wang, D, Bierwagen, GP, “Sol–Gel Coatings on Metals for Corrosion Protection—Review.” Prog. Org. Coat., 64 327–338 (2009)

    CAS  Article  Google Scholar 

  3. 3.

    Mitton, DB, Carangelo, A, Acquesta, A, Monetta, T, Curioni, M, Bellucci, F, “Selected Cr(VI) Replacement Options for Aluminum Alloys: A Literature Survey.” Corros. Rev., 35 (6) 365–382 (2017)

    CAS  Article  Google Scholar 

  4. 4.

    Tsai, ST, ChangJean, WC, Chao, PH, Fu, SY, Tsai, TC, “Whole pH Range Anti-corrosion Property of Aluminum Alloy Coated with MFI Zeolite Film.” Corros. Eng. Sci. Technol., 53 (S1) 34–38 (2018)

    CAS  Article  Google Scholar 

  5. 5.

    Calabrese, L, “Anticorrosion Behavior of Zeolite Coatings Obtained by In Situ Crystallization: A Critical Review.” Mater, 12 (1) 59 (2019)

    CAS  Article  Google Scholar 

  6. 6.

    Zhang, F, Zhao, LL, Chen, HY, Xu, SL, Evans, DG, Duan, X, “Corrosion Resistance of Superhydrophobic Layered Double Hydroxide Films on Aluminum.” Angew. Chem. Int. Ed., 47 2466–2469 (2008)

    CAS  Article  Google Scholar 

  7. 7.

    Evans, DG, Slade, RCT, “Structural Aspects of Layered Double Hydroxides.” In: Duan, X, Evans, DG (eds.) Layered Double Hydroxides. Structure and Bonding. Springer, Berlin (2005)

    Google Scholar 

  8. 8.

    Tedim, J, Poznyak, SK, Kuznetsova, A, Raps, D, Hack, T, Zheludkevich, ML, Ferreira, MGS, “Enhancement of Active Corrosion Protection via Combination of Inhibitor-Loaded Nanocontainers.” ACS Appl. Mater. Interface, 2 1528–1535 (2010)

    CAS  Article  Google Scholar 

  9. 9.

    Neves, CS, Bastos, AC, Salak, AN, Starykevich, M, Rocha, D, Zheludkevich, ML, Cunha, A, Almeida, A, Tedim, J, Ferreira, MGS, “Layered Double Hydroxide Clusters as Precursors of Novel Multifunctional Layers: A Bottom-Up Approach.” Coatings, 9 328 (2019)

    CAS  Article  Google Scholar 

  10. 10.

    Alibakhshi, E, Ghasemi, E, Mahdavian, M, Ramezanzadeh, B, Farashi, S, “Active Corrosion Protection of Mg-Al-PO43− LDH Nanoparticle In Silane Primer Coated with Epoxy on Mild Steel.” J. Taiwan Inst. Chem. Eng., 75 248–262 (2017)

    CAS  Article  Google Scholar 

  11. 11.

    Tedim, J, Zheludkevich, ML, Bastos, AC, Salak, AN, Lisenkov, AD, Ferreira, MGS, “Influence of Preparation Conditions of Layered Double Hydroxide Conversion Films on Corrosion Protection.” Electrochim. Acta, 117 164–171 (2014)

    CAS  Article  Google Scholar 

  12. 12.

    Galvão, TLP, Neves, CS, Zheludkevich, ML, Gomes, JRB, Tedim, J, Ferreira, MGS, “How Density Functional Theory Surface Energies May Explain the Morphology of Particles, Nanosheets, and Conversion Films Based on Layered Double Hydroxides.” J. Phys. Chem. C, 121 2211–2220 (2017)

    Article  Google Scholar 

  13. 13.

    Guo, X, Xu, S, Zhao, L, Lu, W, Zhang, F, Evans, DG, Duan, X, “One-Step Hydrothermal Crystallization of a Layered Double Hydroxide/Alumina Bilayer Film on Aluminum and Its Corrosion Resistance Properties.” Langmuir, 25 9894–9897 (2009)

    CAS  Article  Google Scholar 

  14. 14.

    Liu, Y, Wang, N, Caro, J, “In Situ Formation of LDH Membranes of Different Microstructures with Molecular Sieve Gas Selectivity.” J. Mater. Chem. A, 2 5716–5723 (2014)

    CAS  Article  Google Scholar 

  15. 15.

    Yan, TT, Xu, S, Peng, Q, Zhao, L, Zhao, X, Lei, XD, Zhang, F, “Self-healing of Layered Double Hydroxide Film by Dissolution/Recrystallization for Corrosion Protection of Aluminum.” J. Electrochem. Soc., 160 (10) C480–C486 (2013)

    CAS  Article  Google Scholar 

  16. 16.

    Zhang, Y, Li, Y, Ren, Y, Wang, H, Chen, F, “Double-Doped LDH Films on Aluminum Alloys for Active Protection.” Mater. Lett., 192 33–35 (2017)

    CAS  Article  Google Scholar 

  17. 17.

    Yasakau, AA, Kuznetsova, A, Kallipa, S, Starykevich, M, Tedim, J, Ferreira, MGS, Zheludkevich, ML, “A Novel Bilayer System Comprising LDH Conversion Layer and Sol-Gel Coating for Active Corrosion Protection of AA2024.” Corros. Sci., 143 299–313 (2018)

    CAS  Article  Google Scholar 

  18. 18.

    Ding, C, Tai, Y, Wang, D, Tan, L, Fu, J, “Superhydrophobic Composite Coating with Active Corrosion Resistance for AZ31B Magnesium Alloy Protection.” Chem. Eng. J., 357 518–532 (2019)

    CAS  Article  Google Scholar 

  19. 19.

    Cheng, J, Liang, W, Hu, Y, Chen, Q, “Development of a New Alkali Resistant Coating.” J. Sol-Gel Sci. Technol., 27 309–313 (2003)

    CAS  Article  Google Scholar 

  20. 20.

    Figueira, RB, Silva, CJR, Pereira, EV, “Hybrid Sol–Gel Coatings for Corrosion Protection of Hot-Dip Galvanized Steel in Alkaline Medium.” Surf. Coat. Technol., 265 191–204 (2015)

    CAS  Article  Google Scholar 

  21. 21.

    Li, L, Shi, J, “In Situ Assembly of Layered Double Hydroxide Nano-crystallites within Silica Mesopores and Its High Solid Base Catalytic Activity.” Chem. Commun., 8 996–998 (2008)

    Article  Google Scholar 

  22. 22.

    Legrouri, A, Badreddine, M, Barroug, A, Roy, AD, Besse, JP, “Influence of pH on the Synthesis of the Zn–Al–Nitrate Layered Double Hydroxide and the Exchange of Nitrate by Phosphate Ions.” J. Mater. Sci. Lett., 18 1077–1079 (1999)

    CAS  Article  Google Scholar 

  23. 23.

    Dutta, K, Das, S, Pramanik, A, “Concomitant Synthesis of Highly Crystalline Zn–Al Layered Double Hydroxide and ZnO: Phase Interconversion and Enhanced Photocatalytic Activity.” J. Coll. Interface Sci., 366 28–36 (2012)

    CAS  Article  Google Scholar 

Download references

Acknowledgments

We gratefully acknowledge the financial support from the Ministry of Science and Technology of the Republic of China.

Author information

Affiliations

Authors

Corresponding author

Correspondence to Tseng-Chang Tsai.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Liu, PY., Tsai, CC., Tsai, ST. et al. Poly(methyl methacrylate) intercalated layered double hydroxide film with enhanced alkaline corrosion resistance for aluminum alloy AA6061. J Coat Technol Res (2021). https://doi.org/10.1007/s11998-020-00442-0

Download citation

Keywords

  • LDH coating
  • Oriented film
  • Alkaline corrosion resistance
  • Aluminum alloy
  • Polymer functionalization