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Nanoclay-based self-healing, corrosion protection coatings on aluminum, A356.0 and AZ91 substrates

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Abstract

Investigations were carried out to explore the feasibility of using Ce3+/Zr4+ encapsulated in environmental friendly nanoclay containers for prolonged corrosion protection of pure aluminum, aluminum alloy A356.0 and Mg alloy AZ91. Dimensions of clay nanotubes were studied using SEM and TEM analysis. They were subjected to pore volume and surface area analysis to confirm the loading of inhibitor into their lumen. The smart nanocontainers loaded with active cationic inhibitor were dispersed in an organic–inorganic hybrid sol–gel matrix synthesized from the hydrolysis and condensation of glycidoxypropyltrimethoxysilane and tetraethoxysilane. The loading of nanocontainers in the matrix sol was optimized. Coatings were generated on pure Al, A356.0, AZ91 substrates using a dip-coating technique and cured at 130°C for 1 h in air. The coated substrates were characterized for their corrosion resistance using potentiodynamic polarization and electrochemical impedance spectroscopic analysis by exposing them to 3.5 wt% NaCl solution for time intervals varying from 1 to 120 h. Micro-Raman spectroscopic studies were carried out to analyze the chemical composition of phases in the scribed area after exposure to corrosive medium. A few coated aluminum substrates were subjected to scanning vibrating electrode technique experiments to study the self-healing mechanism.

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Acknowledgments

The authors would like to acknowledge the constant support provided by Dr. G. Sundararajan and Dr. G. Padmanabham throughout the course of this investigation. Authors would like to thank S. Pavithra for the technical support during initial stages of this work. The authors gratefully acknowledge Dr. Neha Y. Hebalkar for useful discussions on BET pore volume analysis; Mr. E. Konda for data acquisition of BET pore volume and surface area of the samples and Mr. G. V. R. Reddy for SEM data analysis. S. Manasa and R. Subasri would like to acknowledge the financial support from SERB, DST for the funding provided through Grant Number SB/S3/ME/007/2014. T. Siva and S. Sathiyanarayanan thank CSIR, New Delhi, for financial support through 12 FYP project Intelcoat (CSC0114).

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Authors and Affiliations

  1. Centre for Sol–Gel Coatings, International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Balapur, Hyderabad, Telangana State, 500005, India

    S. Manasa & R. Subasri

  2. Centre for Materials Characterization and Testing, International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Balapur, Hyderabad, Telangana State, 500005, India

    A. Jyothirmayi & M. Ramakrishna

  3. Corrosion and Materials Protection Division, CSIR-Central Electrochemical Research Institute, Karaikudi, Tamil Nadu, 630006, India

    T. Siva & S. Sathiyanarayanan

  4. Centre for Solar Energy Materials, International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Balapur, Hyderabad, Telangana State, 500005, India

    B. V. Sarada

  5. Department of Chemistry, National Institute of Technology, Warangal, Telangana State, 506004, India

    S. Manasa & K. V. Gobi

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  1. S. Manasa
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  2. A. Jyothirmayi
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  3. T. Siva
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  4. B. V. Sarada
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  5. M. Ramakrishna
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  6. S. Sathiyanarayanan
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  7. K. V. Gobi
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  8. R. Subasri
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Correspondence to R. Subasri.

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Manasa, S., Jyothirmayi, A., Siva, T. et al. Nanoclay-based self-healing, corrosion protection coatings on aluminum, A356.0 and AZ91 substrates. J Coat Technol Res 14, 1195–1208 (2017). https://doi.org/10.1007/s11998-016-9912-3

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  • DOI: https://doi.org/10.1007/s11998-016-9912-3

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