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<p>Organic-inorganic hybrid sol-gel coatings are effective and environmentally friendly alternatives to chromium(VI) pretreatment for aluminum alloys. The advantage of preparing coatings via the sol-gel method is that it allows obtaining coatings with optimized properties by varying synthesis parameters. In this work, a γ-GPS-ZrO<sub>2</sub> hybrid sol for surface pretreatment of AA2024-T3 was prepared by mixing pre-synthesized nano-zirconia (ZrO<sub>2</sub>) sol into hydrolyzed γ-glycidyl etheroxypropyltrimethoxysilane (γ-GPS). Sol-gels with Si-Zr molar ratios of 2, 3, and 4 were applied to the aluminum alloy surface by coating and cured in an oven at 70 °C to form films. Electrochemical impedance spectroscopy (EIS) was used to evaluate the corrosion behavior of the sol-gel coatings on the aluminum alloy surface in 0.5 M NaCl solution. The morphology and chemical structure of the prepared hybrid coatings were analyzed by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), Fourier transform infrared spectroscopy (FTIR), and X-ray photoelectron spectroscopy (XPS). Results show that increasing the Zr-Si molar ratio enhances the crosslinked inorganic network in the sols, leading to increased initial coating resistance and corrosion resistance. However, this also reduces the connectivity of the organic network, enhancing coating hydrophilicity and promoting water-induced degradation, which negatively impacts corrosion resistance. In this study, balancing these opposing trends (corrosion resistance vs. hydrophilicity) was achieved at a Si-Zr molar ratio of 3, yielding coatings with optimal comprehensive performance.</p><p></p>

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Preparation of γ-GPS-ZrO2 hybrid coating by sol-gel method and its synergistic enhancement effect on corrosion resistance and adhesion of AA2024 aluminum alloy

  • 期刊论文

  • 发表日期：

    2025年10月3日

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  • Wang Zhenzhen,
  • Ouyang Chunming,
  • Feng Zhihui,
  • Ma Yongcun,
  • Peng Shusen

摘要

Organic-inorganic hybrid sol-gel coatings are effective and environmentally friendly alternatives to chromium(VI) pretreatment for aluminum alloys. The advantage of preparing coatings via the sol-gel method is that it allows obtaining coatings with optimized properties by varying synthesis parameters. In this work, a γ-GPS-ZrO2 hybrid sol for surface pretreatment of AA2024-T3 was prepared by mixing pre-synthesized nano-zirconia (ZrO2) sol into hydrolyzed γ-glycidyl etheroxypropyltrimethoxysilane (γ-GPS). Sol-gels with Si-Zr molar ratios of 2, 3, and 4 were applied to the aluminum alloy surface by coating and cured in an oven at 70 °C to form films. Electrochemical impedance spectroscopy (EIS) was used to evaluate the corrosion behavior of the sol-gel coatings on the aluminum alloy surface in 0.5 M NaCl solution. The morphology and chemical structure of the prepared hybrid coatings were analyzed by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), Fourier transform infrared spectroscopy (FTIR), and X-ray photoelectron spectroscopy (XPS). Results show that increasing the Zr-Si molar ratio enhances the crosslinked inorganic network in the sols, leading to increased initial coating resistance and corrosion resistance. However, this also reduces the connectivity of the organic network, enhancing coating hydrophilicity and promoting water-induced degradation, which negatively impacts corrosion resistance. In this study, balancing these opposing trends (corrosion resistance vs. hydrophilicity) was achieved at a Si-Zr molar ratio of 3, yielding coatings with optimal comprehensive performance.