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The formation and corrosion behavior of a zirconium-based conversion coating on the aluminum alloy AA6061

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Abstract

To understand the mechanism of the coating formation, the formation process of a zirconium-based conversion coating on aluminum alloy 6061 has been studied by means of AFM in PeakForce Kelvin Probe Force Microscope (PF-KPFM) mode which could provide direct evidence for the existence of driving force for the film formation. In addition, various techniques including SEM, XPS, EIS, salt spray test, and scanning electrochemical microscope were used to investigate the surface state and corrosion behavior of the conversion film. The direct driving force for the coating formation is the Volta potential difference between the intermetallic particles and matrix. That difference produces an ocean of micro electrochemical cells in which the intermetallic particles act as cathodic sites for the film deposition. However, the precipitation of the layer is a self-limited process in which the driving force gradually decreases as the conversion layer covers the surface of the aluminum alloys. The anti-corrosion performance of the film is unfavorable compared to the conventional chromate conversion coatings due to the pitting corrosion that occurs when exposed to harsh environment containing chloride. Furthermore, the zirconium-based conversion coating possesses no self-healing ability leading to the continuous degradation of the film until it completely lose efficacy.

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Acknowledgments

This authors gratefully acknowledge financial support from the National Natural Science Foundation of China (Nos. 50701006 and 51271031), the Fundamental Research Funds for the Central Universities (FRF-SD-12-027A and FRF-BR-13-034), National Basic Research Program of China (973 Program) (No. 2014CB643300), and the National Environmental Corrosion Platform (NECP).

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Authors and Affiliations

  1. Institute of Advanced Materials and Technology, University of Science and Technology Beijing, No. 30 Xueyuan Rd., Haidian Distr.,, Beijing, 100083, People’s Republic of China

    Dongdong Peng, Junsheng Wu, Xiaoli Yan, Xiaoqiong Du, Yueying Yan & Xiaogang Li

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  1. Dongdong Peng
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  2. Junsheng Wu
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  3. Xiaoli Yan
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Correspondence to Junsheng Wu.

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Peng, D., Wu, J., Yan, X. et al. The formation and corrosion behavior of a zirconium-based conversion coating on the aluminum alloy AA6061. J Coat Technol Res 13, 837–850 (2016). https://doi.org/10.1007/s11998-016-9789-1

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  • DOI: https://doi.org/10.1007/s11998-016-9789-1

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