(Invited) Multiscale Electrochemical Analysis of Sol-Gel Films Modified with Eco-Friendly Corrosion Inhibitors for Active Corrosion Protection of AZ61 Magnesium Alloy
Authors: Garcia-Galvan Federico R. , Martín Cordón Jesús , Carmona Noemí , Llorente Irene , Fajardo Santiago , Feliu Sebastian , Galvan Juan Carlos , Barranco Violeta 
Published: February 2024

The use of magnesium and its alloys has increased in recent years due to their low weight, high strength, excellent machinability, and high dimensional durability. Therefore, they have found application in communications, automotive and aerospace industries, among others. However, their high negative reduction potentials, low chemical stability, and the unstable native oxide films have limited their use, particularly in applications that require high corrosion resistance.1
-3 The application of sol-gel coatings has shown to be an effective method to overcome this problem. In this context, the aim of this study was to develop sol-gel thin-films doped with ecological corrosion inhibitors for corrosion protection of AZ61 alloy surfaces. The objective was to determine whether these new systems could provide an alternative to the replacement of chromates, surface pre-treatments and chemical conversion coatings that contain conventional corrosion inhibitors, which are currently being questioned for their harmfulness to health and the environment.4

Methyltriethoxysilane (MTEOS) and tetraethylorthosilicate (TEOS) were used as precursors to produce sols, which were then modified with active corrosion protection dopants. Eco-benign corrosion inhibitors, such as L-cysteine (L-Cys), lanthanum (III) acetate hydrate, and lanthanum (III) isopropoxide were incorporated in the sol-gel matrix as dopants. A set of sol-gel coatings was modified with a common dopant, benzotriazole (BTA), for comparison purposes, as it is a well-known effective corrosion inhibitor. However, this chemical compound is known to be carcinogenic and toxic to flora and fauna, and its use is currently being restricted today in compliance with environmental protection regulations.5,6

The resulting sols were processed and deposited on AZ61 substrates by dip-coating technique, producing transparent sol-gel thin-films. The thickness of the films was evaluated by interference of reflection spectra. Their chemical composition was characterized by X-ray fluorescence (XRF), while surface chemical composition and oxidation state of elements present at the outermost surface nanolayers was also analysed by X-ray photoelectron spectroscopy (XPS). The structural and thermal characterization of the doped thin-films were respectively analysed by Fourier transformed infrared spectroscopy (FTIR) and thermogravimetry and differential thermal analysis (TG/DTA).

The corrosion protection behaviour of the sol-gel coatings during immersion tests in 0.006 M and 0.6 M NaCl aqueous solutions was studied using a multiscale electrochemical approach. Global electrochemical impedance spectroscopy (EIS) was used for macroscopic scale characterisation. Localised electrochemical impedance spectroscopy (LEIS and LEIM) was used for the characterisation at micro- and sub-microscopic scales using an electrochemical minicell system and a scanning electrochemical workstation.

The texture and microstructure of coated samples before and after corrosion tests were observed by optical and scanning electron microscopies (OM and SEM), while topography and coating roughness were analysed by atomic force microscopy (AFM).

In terms of corrosion resistance, similar results were obtained with sol-gel thin-films doped with lanthanum acetate or lanthanum isopropoxide. The synthesis method of the acetate-doped gels is much simpler and cheaper, so from a practical standpoint, these sol-gel thin-films could be more interesting. On the other hand, highly satisfactory results were obtained with gels doped with non-toxic L-Cys compared with those doped with BTA. Finally, it is noteworthy that an interesting synergistic effect was observed in the corrosion protection of the AZ61 alloy in sol-gel coatings that were doped with metal-organic inhibitors and loaded with organic inhibitors (L-Cys or BTA).

As a concluding remark, this study has provided an effective and environmentally friendly solution for the active corrosion protection of the AZ61 alloy. Sol-gel thin-films doped with eco-friendly corrosion inhibitors have showed promising results in extending the durability of AZ61 alloy while being sustainable. The multiscale electrochemical approach used has provided a comprehensive understanding of the active corrosion protection behaviour and the self-healing properties of sol-gel coatings, which can be extended to other materials and systems.

Funding Sources

This work has been supported by the Ministry of Science and Innovation (MCINN, Spain) through the Project PID2019-104717RB-I00.

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