• Corrosion Science and Technology
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• v.6 no.4
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• pp.206-210
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• 2007

Aerospace aluminum alloys such as Al alloy 2024-T3 and 7075-T6 are subject to localized corrosion due the existence of intermetallics containing Cu, Mg or Zn. Chromate is currently widely used in the aerospace industry as the corrosion inhibitor for these alloys. However, chromate needs to be replaced due to its strong carcinogenicity. In this study, an extensive pigment screening has been performed to find replacements for chromates. Different categories of inhibitors were evaluated by immersion tests, DC polarization tests and other methods. Phosphates, zinc salts, cerium salts, vanadates and benzotriazole were found to be effective inhibitors for AA7075. Among those inhibitors, zinc phosphate was found to be the most effective in our novel, silane-based, one-step aqueous primer system. The performance of this primer is comparable to that of currently used chromate primers in accelerated corrosion tests, while it is completely chromate-free and its VOC is about 80% less than that of current primers. Studies by SEM/EDS showed that the unique structure of the superprimer accounts for the strong anti-corrosion performance of the zinc phosphate pigment. The self-assembled stratified double-layer structure of the superprimer is characterized by a less-penetrable hydrophobic layer at the top and a hydrophilic layer accommodating the inhibitors underneath. The top layer functions as the physical barrier against water ingress, while the lower layer functions as a reservoirfor the inhibitor, which is leached out only if the coating is damaged by a scratch or scribe. The presence of a silane in the primer further improves the adhesion and anti-corrosion performance of the primer.

• Corrosion Science and Technology
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• v.5 no.3
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• pp.94-98
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• 2006

The next generation nuclear power reactor will use Pb-Bi as the cooling material. The steel structure materials such as HT-9 used in the reactor suffer from corrosion when they are exposed to high temperature Pb-Bi. Therefore corrosion should be prevented to use Pb-Bi as the coolant material without any safety problem. One method is to control the oxygen content in Pb-Bi. An appropriate amount of oxygen in Pb-Bi can produce a thin oxide layer on steel, and this layer protects the steel from corrosion attack. Since the required oxygen content in Pb-Bi is in the range of $10^{-5}$ to $10^{-7}$ wt%, this small oxygen content can be controlled by flowing a mixture of hydrogen gas and water vapor. The stagnant corrosion test of HT-9 samples was performed by controlling the oxygen content up to 2,000 hours. The corrosion behavior of HT-9 was analyzed at the temperatures of $500^{\circ}C$ and $650^{\circ}C$ with a reduced condition and a oxygen content of $10^{-6}$ wt%.

• Corrosion Science and Technology
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• v.7 no.6
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• pp.315-318
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• 2008

The atmospheric corrosion performance of Al-alloying, Si-alloying and Al-Si-alloying steel were studied by wet/dry cyclic corrosion tests (CCT) at $30^{\circ}C$ and 60% relative humidity (RH). The corrosion electrolyte used for CCT was 0.052 wt% $NaHSO_{3}$ (pH~4) solution. The result of gravimetry demonstrated that Al-Si-bearing steels showed lower corrosion resistance than other rusted steels. But the rusted 0.7%Si-alloying steel showed a better corrosion resistance than rusted mild steel. Polarization curves demonstrated that Al-/Si-alloying and Al-Si-alloying improved the rest potential of steel at the initial stage; and accelerated the cathodic reduction and anodic dissolution after a rust layer formed on the surfaces of steels. XRD results showed that Al-Si-alloying decreased the volume fraction of $Fe_{3}O_{4}$ and $\alpha-FeOOH$. The recycle of acid accelerated the corrosion of steel at the initial stage. After the rust layer formed on the steel, the leak of rust destabilized the rust layer due to the dissolution of compound containing Al (such as $FeAl_{2}O_{4}$, $(Fe,\;Si)_{2}(Fe,\;Al)O_{4}$). Al-Si-alloying is hence not suitable for improving the anti-corrosion resistance of steel in industrial atmosphere.

• Journal of Welding and Joining
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• v.33 no.1
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• pp.49-53
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• 2015

An experimental study was conducted to investigate the effect of carbon nanotubes on the zinc corrosion resistance of sealing layer formed on the Tungsten Carbide spray coating. Using the nanotubes, a sealing agent in the form of solid-liquid suspensions was made and applied to the surface of spray coating. A series of experiments, consisted of three stages such as preparation of test piece, molten-pot immersion test, and evaluation of micro structure, were undertaken to demonstrate complicated interaction existing between zinc ions and sealing layer containing the nanotubes. Experimental results showed newly developed sealing layer were less susceptible to corrosion and thus coated layer was well protected even in the case of 10 days exposure. Comparison of the micro structure after molten pot test also indicated that carbon nanotubes still remained in the matrix and organized more reliable frame work constituted with boron nitride and chromium compound. It was revealed that carbon nanotubes in the sealing layer played positive role to enhance zinc corrosion resistance in the perspective of both fibrous structure and inherent chemical stability.

• Corrosion Science and Technology
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• v.23 no.3
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• pp.179-194
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• 2024

A layer-by-layer coating was produced using electrophoretic deposition for a HA/Al₂O₃ coating layer and a bioglass coating layer on Co-Cr-Mo alloy with a roughness of 0.5 ㎛ (400 emery paper SiC). The corrosion behaviour was analyzed by assessing the coating layers' exceptional corrosion resistance, which outperformed the substrate. Cr ion release test using AAS was carried out, indicating that factional graded coating inhibited ion release from the uncoated substrate to coated sample. The porosity was expressed as a percentage, representing the extent of imperfections on the surface of all coatings. These imperfections fell within an acceptable range of 1% to 3%. The roughness of the coated surface was measured using atomic force microscopy, which revealed an excellent roughness value of 3.32 nm. Tape test technique for adhesion revealed that the removal area of the substrate coating layer varied by 11.92%. X-ray diffraction analysis confirmed the presence of all coating material peaks and verified phases of the deposited coating layers. These findings provided evidence that the coating composition remains unaffected by the electrophoretic deposition process. The bioactivity was assessed by immersion in a simulated bodily fluid, which revealed the formation of HCA during a period of 5 days.

• ETRI Journal
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• v.21 no.3
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• pp.16-21
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• 1999

After etching Al-Cu alloy films using SiCl4/Cl_2/He/CHF3 mixed gas plasma, the corrosion phenomenon at the grain boundary of the etched surface and a passivation layer on the etched surface with an SF6 plasma treatment subsequent to the etching were studied. In Al-Cu alloy system, corrosion occurs rapidly on the etched surface by residual chlorine atoms, and it occurs dominantly at the grain boundaries rather than the crystalline surfaces. To prevent corrosion, the SF6 gas plasma treatment subsequent to etching was carried out. The passivation layer is composed of fluorine-related compounds on the etched Al-Cu surface after the SF6 treatment, and it suppresses effectively corrosion on the surface as the SF6 treatment pressure increases. Corrosion could be suppressed successfully with the SF6 treatment at a total pressure of 300 mTorr. To investigate the reason why corrosion could be suppressed with the SF6 treatment, behaviors of chlorine and fluorine were studied by various analysis techniques. It was also found that the residual chlorine incorporated at the grain boundary of the etched surface accelerated corrosion and could not be removed after the SF6 plasma treatment.

• Journal of Ocean Engineering and Technology
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• v.15 no.3
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• pp.69-74
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• 2001

This paper was to investigate of a adhesiveness for the plasma sprayed coating materials did salt spray by acoustic emission method in tensile loadings. The powders used for the coating were nickel aluminum composite powder Ni-4.5wt.%Al and titanium dioxide powder $TiO_2$. These powders were coated on a carbon steel S45C by plasma spray method. The result solution was a 5% NaCl and the slat spray times were 2, 5 and 10 hours respectively. The salt solution penetrated into the surface of the substrate through pore of the coating layer built in the process of plasma spay. Corrosion productions formed on the surface of substrate. The adhesiveness between the substrate and the coating layer is weaken by corrosion and the exfoliation initiated chiefly at the corrosion surface of the substrate. The AE events and energy of the corroded coating specimens decreased as the salt spray times increased.

• Journal of the Korean Society for Nondestructive Testing
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• v.26 no.6
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• pp.417-426
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• 2006

A Digital X-ray imaging system using Compton backscattering has been developed to obtain a cross-sectional profile and mass loss of corroded lap-splices of aging aircraft from density variation. A slit-type camera was designed to focus on a small scattering volume inside the material, from which the backscattered photons are collected by a collimated scintillator detector for interpretation of material characteristics. The cross section of the lap-joint is scanned by moving the scattering volume through the thickness direction of the specimen. The mass loss of each layer has been estimated from a Compton backscatter A-scan to obtain the thickness of each layer including the aluminum sheet, the corrosion layer and the sealant. Quantitative information such as location and width of planar corrosion in the lap splices of fuselages is obtained by deconvolution using a nonlinear least-square error minimization method(BFGS method): A simple reconstruction model is also introduced to overcome distortion of the Compton backscatter data due to attenuation effects attributed to beam hardening and quantum noise.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2001.05a
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• pp.344-349
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• 2001

This paper was to investigate of a adhesiveness for the plasma sprayed coating materials did salt spray by acoustic emission method in tensile loadings. The powders used for the coating were nickel aluminum composite powder Ni-4,5wt.%Al and titanium dioxide powder Ti02. These powders were coated on a carbon steel S45C by plasma spray method. The salt solution was a 5% NaCl and the salt spray times were 2, 5 and 10 hours respectively. The salt solution penetrated into the surface of the substrate through pore of the coating layer built in the process of plasma spay. Corrosion productions formed on the surface of substrate. The adhesiveness between the substrate and the coating layer is weaken by corrosion and the exfoliation initiated chiefly at the corrosion surface of the substrate. The AE events and energy of the corroded coating specimens decreased as the salt spray times increased.

• Journal of the Korean institute of surface engineering
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• v.50 no.5
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• pp.339-344
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• 2017

Highly corrosion resistance performance of CrAlSiN coatings were obtained by applying ultrathin $Al_2O_3$ thin films using atomic layer deposition (ALD) method. CrAlSiN coatings were prepared on Cr adhesion layer/SUS304 substrates by a hybrid coating system of arc ion plating and high power impulse magnetron sputtering (HiPIMS) method. And, ultrathin $Al_2O_3$ passivation layer was deposited on the CrAlSiN/Cr adhesion layer/SUS304 sample to protect CrAlSiN coatings by encapsulating the whole surface defects of coating using ALD. Here, the high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) and energy dispersive X-ray spectrometry (EDX) analysis revealed that the ALD $Al_2O_3$ thin films uniformly covered the inner and outer surface of CrAlSiN coatings. Also, the potentiodynamic and potentiostatic polarization test revealed that the corrosion protection properties of CrAlSiN coatings/Cr/SUS304 sample was greatly improved by ALD encapsulation with 50 nm-thick $Al_2O_3$ thin films, which implies that ALD-$Al_2O_3$ passivation layer can be used as an effect barrier layer of corrosion.