Morphology and corrosion resistance of composite coatings obtained by phosphating and molybdate post-sealing on galvanized steel

The phosphated hot-dip galvanized(HDG) sheets were post-sealed with sodium molybdate solution to improve the corrosion resistance of phosphate coatings. The morphology,chemical composition and corrosion resistance of the coatings were investigated using scanning electron microscopy(SEM),energy dispersive spectroscopy(EDS),Tafel polarization measurements and neutral salt spray(NSS) tests,and were compared with those of the single coatings. The results show that post-sealing the phosphated HDG steel with molybdate solution,the pores among the zinc phosphate crystals are sealed with molybdate films containing Zn,P,O and Mo,and the continuous composite coatings are formed. The suppression of both the anodic and the cathodic processes of zinc corrosion on the samples are enhanced significantly. The synergistic corrosion protection effect of the single phosphate coatings and molybdate films for zinc is evident. The corrosion resistance of the composite coatings increases with phosphating time up to 300 s.

Effect of silicate pretreatment, post-sealing and additives on corrosion resistance of phosphated galvanized steel

Sodium silicate (water glass) pretreatment before phosphating, silicate post-sealing after phosphating and adding silicate to a traditional phosphating solution were respectively carried out to obtain the improved phosphate coatings with high corrosion resistance and coverage on hot-dip galvanized(HDG) steel. The corrosion resistance, morphology and chemical composition of the coatings were investigated using neutral salt spray(NSS) tests, scanning electron microscopy(SEM) and energy dispersive spectroscopy(EDS). The results show that pretreatment HDG steel with silicate solutions, phosphate coatings with finer crystals and higher coverage are formed and the corrosion resistance is enhanced. Adding silicate to a traditional phosphating solution, the surface morphology of the coatings is nearly unchanged. The corrosion resistance of the coatings is mainly dependent on phosphating time. Phosphating for a longer time (such as 5 min), the corrosion resistance, increasing with concentration of silicate, is improved significantly. Post-sealing the phosphated HDG steel with silicate solutions, the pores among the zinc phosphate crystals are sealed with the films containing Si, P, O and Zn and the continuous composite coatings are formed. The corrosion resistance of the composite coatings, related to the pH value, contents of hydrated gel of silica and Si 2O52?and post-sealing time, is increased markedly. The improved coatings with optimal corrosion resistance are obtained for phosphating 5 min and post-sealing with 5 g/L silicate solution for 10 min.

Growth and corrosion behavior of molybdate passivation film on hot dip galvanized steel

Hot dip galvanized steel sheets were passivated by molybdate aqueous solution containing 10 g/L Na 2MoO 4·2H 2O, and the growth behavior and corrosion resistance of the passivation film were investigated. In the initial stage of passivation, the mass gain of film increases with passivation time proportionally. The film grows up more quickly and is apt to cracking at grain boundaries of zinc, then the cracks spread gradually on the whole surface of the film, and eventually the film will flake off with the increasing of film thickness. XPS results indicate that Mo compounds are present in Mo(Ⅵ) state on the surface of the film, and Mo(Ⅵ) and Mo(Ⅳ) states inside the film. NSS test shows that, the corrosion resistance of the passivation film decreases as the cracks occur, but in AASS test, the thicker the film is, the better the corrosion resistance is, the cracks of film have little effect on the corrosion resistance.

Cerium-tannic acid passivation treatment on galvanized steel

A novel cerium-tannic acid passivation treatment was performed on galvanized steel. The corrosion resistance of cerium-tannic passivated samples was tested by dropping test with 0.5 wt.% CuSO4 aqueous solution. The mass loss per unit area of passivated samples was measured after the corrosion in 0.5 mol/L NaCl ＋ 0.005 mol/L H2SO4 at room temperature for 96 h. The electrochemical behaviors of cerium, tannic acid, and cerium-tannic acid passivated samples on galvanized steel in 0.5 mol/L NaCl solution were investigated by polarization curves and electrochemical impendence spectra. The corrosion equivalent circuit was established according to the impedance characteristics. The results show that cerium-tannic acid treated samples exhibit better corrosion resistance than the sole cerium or tannic acid treated samples under the same condition. The mechanism of synergistic effect for cerium-tannic acid passivation on galvanized steel was discussed.

Effect of microstructure and passive film on corrosion resistance of 2507 super duplex stainless steel prepared by different cooling methods in simulated marine environment

The effect of microstructure and passive film on the corrosion resistance of 2507 super duplex stainless steel(SDSS)in simulated marine environment was investigated by electrochemical measurements,periodic wet–dry cyclic corrosion test,scanning Kelvin probe force microscopy,atomic force microscopy,and X-ray photoelectron spectrometry.The results show that the occupation ratio ofγphase increases with the decrease in cooling rate,whereas the content ofαphase reduces gradually.In addition,theσprecipitated phase only emerges in the annealed steel.The pitting sensitivity and corrosion rate of 2507 SDSS reduce first and then increase as the cooling rate decreases.Theσprecipitated phase drastically reduces the protective ability of the passive film and facilitates micro-galvanic corrosion of the annealed steel.For various microstructures,the pits are preferentially distributed within theσandγphases.The corrosion resistance of 2507 SDSS prepared by different cooling methods is closely related to the microstructure and structure(stability and homogeneity)of the passive film.Normalized steel shows an optimal corrosion resistance,followed by the quenched and annealed steels.

Structure and Corrosion Resistance of a Composite γ-Amino Propyl Triethoxy Silane and γ-Glycidoxy Propyl Trimethoxy Silane Conversion Coating on Galvanized Steel

In an aqueous solution of the mixtures of γ-amino propyl triethoxy silane and γ-glycidoxy propyl trimethoxy silane, a composite silane conversion coating was developed on galvanized steel. FESEM （field emission scanning electron microscope）, XPS （X-ray photoelectron spectroscopy）, ATR FTIR （attenuated total reflection Flourier transform infrared spectroscopy） and SST （salt spray test） were used to characterize the obtained composite silane conversion coating and also the coating formation process was studied. The result showed that the surface of the composite silane conversion coating was complete, consecutive and compact. The coating could endure a neutral salt spray test for 72 h without corrosion. The result of salt spray test indicated that the composite silane conversion coating can provide a better corrosion inhibition than the coating which was composed of the single silane. Based on observation and analysis, it was proposed that the formation process of the silane coating on zinc should consist of three steps： the hydrolysis of the silane molecules, silane chemical adsorption and silane crosslinking condensation. The crosslinking reactions took place between ~＇-amino propyl triethoxy and ＂/-glycidoxy propyl trimethoxy silane during the forming process of the coating, and a high crosslinked density interpenetrating structure network was obtained, so the composite silane conversion coating could keep the corrosive substances from the zinc more effectively.

Relationship between La and Ce additions on microstructure and corrosion resistance of hot-dip galvanized steel

Scanning electron microscopy,X-ray diffraction,a neutral salt spray test,and electrochemical methods were applied to observe the microstructure and test the corrosion resistance of hot-dip galvanized steel before and after the addition of La and Ce.La/Ce mixture existed in the form of(La,Ce)Zn13 on the coated surface,decreased the coating thickness and accelerated the zinc dendritic growth.The corrosion current density of Zn-0.1La-0.1Ce coating was 63%less than that of pure Zn coating.This phenomenon can be explained that La/Ce mixture inhibited the transformation of Zn5(OH)8Cl2·H2O into Zn5(CO3)2(OH)6 or ZnO,reduced the time for appearance of red rust,and thus enhanced the stability of corrosion products and delayed the oxidation and corrosion processes of galvanized coating.La/Ce mixture improved the corrosion resistance compared to a single La or a single Ce addition.A competitive relationship between La and Ce was observed in the corrosion resistance improvement of hot-dip galvanized steel.

High corrosion resistance 21%Cr-0.4%Cu ferritic stainless steel contributing to resource conservation

With prices for metal resources such as nickel and molybdenum soaring,there is a heightened sense of crisis concerning resource scarcity.While Type304,the most common stainless steel,offers excellent corrosion resistance,its price is affected significantly by the cost of nickel because of its 8%nickel content.The stainless steel that has the same corrosion resistance as that of Type304 and does not contain nickel and molybdenum has been required.JFE Steel Corporation has developed a new 21%Cr-0.4%Cu stainless steel,the world's first ferritic stainless steel,which offers equivalent corrosion resistance to Type304 while containing absolutely no nickel or molybdenum,two rare metals.The newly developed steel contains 21%chromium with the addition of 0.4% copper.The development of the steel is based on a new discovery that the passive films of stainless steels could be strengthened by the synergy effect of high chromium content and copper addition.Copper addition enriches the chromium content in passive films after field exposure.Newly developed 21%Cr-0.4%Cu stainless steel is adopted for many applications as a substitution for Type304,including commercial kitchenware,building materials and industrial machinery.The steel is expected to be a new standard of a ferritic stainless steel as a substitution for Type304.

The development of advanced Cr-free organic composite coated electrogalvanized steel sheet with excellent grounding property

In recent years,the concern about environmental protection is increasing on a world scale.Major manufacturers of home appliances and OA equipment have introduced so-called 'green procurement schemes' for reducing environmentally harmful substances in manufacturing process and end products. Under such background,a new type of chromate-free organic composite coated electro-galvanized steel sheet with high conductivity was developed by Baosteel,which meets the EU RoHS Directive(Restriction of the Hazardous Substances) and other related laws and regulations on environmental safety.It also provides excellent surface electrical conductivity,corrosion resistance,fingerprint resistance,solvent resistance,coating adhesion, heat resistance,formability and other special properties to meet the demand of manufacture's process of OA machine. Compared with previously developed anti-fingerprinting coated electro-galvanized steel sheet,this newly developed product has a good balance between high corrosion resistance(time to 5%white rust in salt spray test is 120 h for flat panel and 72 h for worked potion) and conductivity(surface electro-resistivity in accordance with LOREAST is less than 0.1 milliohm ) due to the special design of coating's structure.Besides,It also provides the properties of grounding and shielding against electromagnetic waves.The evaluation of surface performances of new product showed that it is comparable or even better than the similar products. Currently,the newly developed product has been commercialized. In this paper,the major properties are discussed,such as corrosion resistance,surface electrical conductivity, fingerprint resistance,solvent resistance,coating adhesion(ink/melamine alkyd paint),heat resistance and formability.Furthermore,the application is also briefly described.

Corrosion Resistance of Co-containing Maraging Stainless Steel

Corrosion resistance behavior of Co-containing maraging stainless steels was investigated. Neutral salt spray and polarization test showed that maraging stainless steel with high Co content showed poor corrosion behavior. Microstructure observation proved that segregation of Cr in the matrix deteriorated its corrosion resistance. The surface morphology of the aged maraging stainless steel with high Co content indicated that during passivation process, the newly formed passive film with sinusoidal distribution readily destroyed by the corrosive medium, hence, causing poor corrosion resistance. Moreover, through first-principles calculation it was proved that Co increased Fe–Fe ferromagnetic interaction which facilitated the formation Cr-rich clusters.

Study on lanthanum salt conversion coating modified with citric acid on hot dip galvanized steel

Modified lanthanum salt conversion coatings prepared by rare earth salt route based on lanthanum nitrate solution were proposed as alternatives to the process involving toxic hexavalent chromate.The structure and composition of the coating were determined with X-ray energy dispersive spectrometer and X-ray photoelectron spectroscopy.The surface morphologies of the treated samples were observed with scanning electron microscopy.The natural salt spray and electrochemical impendence spectra tests were carried ...

UV-LED Curing Cationic Passivation Film for the Surface of Hot-Dip Aluminum-Zinc Coated Steel Plate

The surface treatment technology of hot aluminum-zinc steel plate and UV curing technology may be effectively combined in the present research. According to different light curing mechanisms, different formulations from UV curing surface treatment agents can be applied to the surface treatment of hot aluminum-zinc steel plate, mainly including 3-ethyl-3-benzoxy-methyl oxacyclobutane (TCM 104) and 3,4-epoxy-cyclohexylformic acid -3',4'-epoxy-cyclohexyl methyl ester (UVR 6110) as active diluents, high molecular weight polyfunctional oxacyclobutane as oligomer, triaryl sulfonium salt as a cationic photoinitiator, and an anthracene compound as a sensitizer. 385 nm LED lamp used as a radiation resource, the effects of the proportion of active diluent, the type and amount of photoinitiator, the amount of sensitizer, the curing temperature, and the amount of nano-SiO2 on the photocuring rate were investigated by photoper-scanning differential calorimetry (Photo-DSC). The experimental results show that the system has the fastest photocuring rate under the conditions of 8:2 ratio of TCM 104 to UVR 6110, 2.5% photoinitiator, 0.6% sensitizer, 0.2% nano-SiO2 additive, and 80˚C curing temperature. Based on addition of the appropriate number of various additives, the cationic photocuring surface treatment solution was prepared and further coated on the hot-dip galvalume steel plates. After curing, the passivation films were characterized by neutral salt spray test (NSST), Fourier transform infrared spectroscopy (FT-IR), electrochemical testing and other methods. The results show that the formulations could be cured at an energy of 150 mJ/cm2, and the overall performance of the passivation film could meet with the requirements of the downstream users.

微纳米α-Al_(2)O_(3)改性丙烯酸树脂-有机硅烷复合钝化对不锈钢硬度及耐蚀性的影响

通过微纳米α-Al_(2)O_(3)改性丙烯酸树脂-有机硅烷复合而成的无铬钝化液作用于不锈钢基板表面,探究其在不锈钢表面形成的微纳米α-Al_(2)O_(3)钝化膜对不锈钢表层性能的影响。通过表面硬度测试、扫描电镜测试,分析基板表面特征。同时,通过涂层附着力测试和电化学测试,探究涂层的粘结强度和基板的耐蚀性能。结果表明,经微纳米α-Al_(2)O_(3)改性的无铬钝化液使不锈钢板材的耐蚀性显著提升,同时对其表面硬度的提升效果达到80%。

新型前处理工艺在钢铝混合材料上的应用

通过扫描电镜(SEM)、电感耦合等离子体发射光谱仪、循环交变盐雾试验机等设备就后处理技术在钢铝混材表面处理上的应用进行研究。结果表明:车身上的冷轧板、镀锌板经过新型前处理工艺处理后表面形成均匀致密的磷化膜;铝板经过新型前处理工艺处理后,其表面形成钝化膜;随着铝材在钢铝混合材料中占比的提升,磷化渣产生量逐渐降低;当处理材料仅为铁材时,磷化渣量为2.5 g/m^(2),当所处理的材料全部为铝材时,磷化渣量低于0.5g/m^(2);新型前处理工艺处理钢铝混材时,磷化液中离子浓度均保持稳定水平;3种板材的漆膜附着力测试结果均符合标准要求;冷轧板经过1000 h盐雾检测后,单边扩蚀小于2 mm,漆膜未发生起泡和剥离;铝板和镀锌板经过1008h循环交变测试后,单边扩蚀宽度小于2mm,漆膜未发生起泡和剥离。

汽车车身常用板材耐腐蚀性能研究

车身常用板材的耐腐蚀性能是车身板材选用的重要参考标准,因此,对已加工为零件的热浸镀铝硅镀层板、未加工为零件的热浸镀铝硅镀层板、电镀锌板、热镀锌板、热成型钢裸板和冷轧板分别进行裸板材板和电泳板的中性盐雾对比试验。结果表明:有镀层的板材耐腐蚀性能明显优于无镀层板材;热浸镀铝硅镀层板加工成零件后其镀层会被破坏,导致其裸板耐腐蚀性能下降,但其电泳板的耐腐蚀性能加工前后变化不大,划痕扩蚀情况反而提升;热成型钢裸板因加工过程形成的氧化膜和脱碳层,在中性盐雾条件下4 h即出现锈蚀,其电泳板和电泳划痕板中性盐雾试验均出现严重的起泡问题。

全无铬钝化镀锌板成形后的耐腐蚀性能

采用扫描电镜(SEM)和辉光放电光谱仪(GDS)研究了变形量对全无铬钝化镀锌板表面形貌和元素分布的影响。通过电化学分析、中性盐雾试验、循环盐雾试验和硫酸铜点滴试验,对比了不同变形量时全无铬钝化板的耐蚀性。结果表明,当主应变增大到3%时,钝化膜表面开始出现裂纹;随着主应变的继续增大,裂纹尺寸逐渐加大,裂纹主要出现在光整坑内部。随变形量增大,全无铬钝化板的耐蚀性变差。

环保型钢铁钝化耐蚀性及成膜机理

钢铁腐蚀的现象越发普遍,工业上常用磷化作为防止钢铁腐蚀的方法,但磷化对环境污染严重。为了减少磷污染,以Q235钢为基体材料,研发了一种以植酸溶液为基础的环保型钢铁钝化工艺,利用硫酸铜点滴试验和电化学方法测试了环保型钢铁钝化膜的耐蚀性;利用扫描电镜(SEM)观测了钝化膜的成分和微观形貌。结果表明:环保型钢铁钝化后的样品硫酸铜点滴的平均时间达到了107 s,腐蚀电流只有4.3×10^(-3)mA,环保型工艺处理后的钝化膜的阻抗直径和阻抗模量大,其耐腐蚀性能较高。扫描电镜下的环保型钝化膜完整无裂纹,具有良好的耐蚀性能。最后简要分析了环保型钝化膜的成膜机理。

含铜430不锈钢在模拟生理盐水环境下的耐蚀性能研究

为研究含Cu 430不锈钢在生理盐水环境下的腐蚀行为,采用电化学测试方法研究了含Cu 430铁素体不锈钢在模拟生理盐水(质量分数0.9%NaCl)溶液中的耐蚀性能,同时,利用Mott-Schottky曲线和X射线光电子能谱(XPS)对钝化膜的半导体特性和表面成分进行了表征,并借助扫描电镜(SEM)观察了电化学腐蚀后的表面形貌。结果表明,在0.9%的NaCl溶液中,不含Cu和含1.57%Cu(质量分数)的430铁素体不锈钢表面均产生了钝化膜。与不含Cu相比,含1.57%Cu的不锈钢耐蚀性降低。Cu元素对430铁素体不锈钢钝化膜中Cr_(2)O_(3)的形成有抑制作用,从而提高了钝化膜中的缺陷密度。加入Cu元素后,430铁素体不锈钢点蚀坑主要分布在富铜相附近,富铜相破坏了钝化膜的连续性,致使耐蚀性下降,不锈钢表面形貌破坏程度增大。

不同光整工艺对全无铬钝化热镀锌板耐蚀性的影响

分别采用普通磨辊和超精细磨辊对热镀锌板进行光整处理得到不同微观形貌的表面,再进行全无铬钝化处理。对比了采用不同光整工艺时所得全无铬钝化膜的表面形貌和元素分布。通过电化学测试和循环盐雾试验探究了采用不同光整工艺时镀锌板表面无铬钝化膜的耐腐蚀性能。结果表明,超精细磨辊处理后全无铬钝化热镀锌板表面更平坦,钝化膜覆盖更均匀,表面活性位点少,耐腐蚀性能更好。

一种快速评价镀锌钢耐蚀性能的光度分析法

报道了一种以强氧化剂和酸性腐蚀溶液为浸泡液快速评价镀锌钢耐腐蚀性能的新方法。以硫氰酸钾为显色剂,利用分光光度法检测腐蚀溶液中铁离子,对腐蚀溶液的吸光度达某一定值所需时长进行比较,时间越长则表示镀锌层对钢基底保护性能越好。本方法针对目前市场常用镀锌钢,可以在5.5内能够完成一个测试周期。利用显微观察法和盐雾试验验证了此方法的可靠性。本方法操作简单,且大大缩短了腐蚀测试时长,可以实现镀锌钢耐蚀性能的快速评价。