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Chromate-Free Corrosion Inhibition of Aluminum

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Chromate-Free Corrosion Inhibition of Aluminum CHROMATE-FREE CORROSION INHIBITION OF ALUMINUM ALLOYS: VANADATES AND ANIONIC EXCHANGE CLAY PIGMENTS A Dissertation Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Kevin Douglas Ralston, M.S. ***** The Ohio State University 2008 Dissertation Examination Committee: Approved by Professor Rudy Buchheit, Advisor Professor Gerald Frankel _____________________________ Professor Michael Mills Advisor Graduate Program in Materials Professor R. Allen Miller Science and Engineering ABSTRACT In this study, aqueous vanadates and vanadate pigments were studied for possible use as chromate replacements to inhibit corrosion of Al 2024-T3. Vanadate inhibition on Al 2024-T3 was characterized as a function of pH and concentration using anodic and cathodic polarization experiments and scanning electron microscopy (SEM). The results showed a strong correlation between inhibition and the availability of tetrahedrally coordinated vanadate species in test solutions. In particular, solutions containing predominately tetrahedrally coordinated vanadates were observed to act as modest anodic inhibitors and to reduce cathodic kinetics through the suppression of oxygen reduction kinetics. Further, the effect of these tetrahedral vanadates on individual intermetallic particles commonly found in Al 2024-T3 was characterized using a microcapillary electrode. Tetrahedral vanadates were generally found to increase breakdown potentials and decrease cathodic kinetics on all tested materials. Open circuit potential (OCP) was observed to shift in the active direction as a result of decreased cathodic kinetics, just below the observed breakdown potential of Al2CuMg; a phase that plays a critical role in corrosion susceptibility of Al 2024-T3. OCP measurements, SEM images, and potentiostatic hold experiments were used to show suppressed Al2CuMg dissolution and damage accumulation in vanadate solutions. ii Furthermore, synthetic hydrotalcite anion exchange clay pigments were synthesized with vanadates and other possible inhibitor anions. Hydrotalcites allow the use of inhibitors that are too soluble for direct use in organic coatings without leading to coating blistering. A number of hydrotalcite pigments were synthesized and compared to a SrCrO4 standard using electrochemical impedance spectroscopy and salt spray exposure of scribed organically coated panels. Typically, vanadate pigmented PVB coatings were 7 observed to have total impedance within an order of magnitude of SrCrO4 (2 x 10 ohms.cm2). Further, all vanadate coatings were observed to provide some scribe protection during 750 hours of salt spray exposure, however, these coatings also had a tendency to blister. Release from vanadate hydrotalcites was characterized using neutron activation analysis. Interestingly, vanadate hydrotalcite pigments that released relatively small total concentrations of vanadium resulted in the best performance. Low concentrations of vanadium may promote the formation of tetrahedrally coordinated species which were shown to act as inhibitors earlier in this study. iii Dedicated to Robin iv ACKNOWLEDGMENTS I would like to thank my advisor, Dr. Rudy Buchheit, whose encouragement, approach to advising, and patience have allowed me the time to mature and ultimately complete a dissertation, which I would not have believed possible 5 years ago. I also would like to thank Dr. Jerry Frankel who first introduced me to the world of corrosion while I completed my senior project under his supervision. Further, I would like to thank Dr. Mike Mills who provided me with my first experience with materials research when I worked in his lab as an undergraduate. I also wish to acknowledge those who have sponsored portions of my work, namely, the Air Force Office of Scientific Research, Concurrent Technologies, and Luna Innovations. Further, I acknowledge the Journal of the Electrochemistry Society for permission to reproduce significant portions (Chapter 3) of J. Electrochem. Soc., 155, C350 (2008). Copyright 2008, The Electrochemical Society. I would like to thank Dr. T.L. Young for assistance with NMR measurements and Mr. Joe Talnagi for help and guidance in conducting neutron activation analysis. Finally, I wish to thank and acknowledge a number of people who have contributed advice, expertise, and assistance to this work, namely Dr. Nick Birbilis, Dr. Nikki Padgett, Dr. Santi Chrisanti, Dr. Marianno Iannuzzi, Dr. Belinda Hurley, Dr. Sudhaker Mahajanam, Dr. Girdhari Kumar, Hong Guan, Shuyan Qui, and Casey Grimez. v VITA 2003…………………………………B.S. (Materials Science and Engineering), The Ohio State University, Columbus, OH 2006…………………………………M.S. The Ohio State University, Columbus, OH 2003 - Present……………………….Ph.D. The Ohio State University, Columbus, OH PUBLICATIONS 1. K. D. Ralston, S. Chrisanti, T. L. Young, and R. G. Buchheit (2008) Corrosion Inhibition of Aluminum Alloy 2024-T3 by Aqueous Vanadium Species, Journal of the Electrochemical Society 155 (7): C350-C359. 2. P. J. Wurm, P. Kumar, K. D. Ralston, M. J. Mills, and K. H. Sandhage (2002) Fabrication of Light Weight Oxide/Intermetallic Composites at 1000°C by the Displacive Compensation of Porosity (DCP) Method, Ceramic Transactions, 93-101. 3. P. J. Wurm, P. Kumar, K.D. Ralston, M. J. Mills, and K. H. Sandhage (2001) Fabrication of Dense, Lightweight, Oxide-Rich Oxide/Aluminide Composites at 1000oC by the Displacive Compensation of Porosity (DCP) Process, Powder Materials: Current Research and Industrial Practices (2001 TMS Fall Meeting), November 4-8, 129-139. vi FIELDS OF STUDY Major Fields: Materials Science and Engineering vii TABLE OF CONTENTS Page ABSTRACT ii DEDICATION iv ACKNOWLEDGMENTS v VITA vi LIST OF TABLES xiv LIST OF FIGURES xv 1. INTRODUCTION 1 2. LITERATURE REVIEW 6 2.1 Introduction 6 2.2 Aluminum 2024-T3 Metallurgy, Microstructure, and Corrosion Susceptibility 8 2.2.1 Aluminum Alloy 2024-T3 Metallurgy and Microstructure 8 2.2.2 Aluminum 2024-T3 Susceptibility to Localized Corrosion 11 2.2.3 Importance of Al2CuMg (S Phase) 13 2.3 Chromate Background and Toxicity 14 2.3.1 Aqueous Chemistry of Chromate 14 2.3.2 Chromate as Anodic and Cathodic Inhibitors 15 2.3.3 Functionalizing Chromates as Films and Pigments 17 viii 2.4 Vanadate Inhibitors as Possible Alternatives to Chromate 20 2.4.1 Vanadate Background and Toxicity 20 2.4.2 Vanadates as Inhibitors of Corrosion 21 2.4.3 Aqueous Speciation of Vanadate 22 2.4.4 Current Understanding of the Mechanism of Vanadate Inhibition 25 2.4.5 Vanadates Functionalized in Films and Coatings 27 2.5 Hydrotalcite Pigments 29 2.5.1 Structure of Hydrotalcite and Hydrotalcite-like Materials 29 2.5.2 Synthesis of Hydrotalcite-like Materials 32 2.5.3 Anion Exchange and Selectivity 33 2.5.4 Hydrotalcites in Coatings 34 2.6 Critical Issues 35 3. CORROSION INHIBITION OF ALUMINUM ALLOY 2024-T3 BY AQUEOUS VANADIUM SPECIES 53 3.1 Introduction 53 3.2 Experimental Procedures 55 3.2.1 Materials and Chemicals 55 3.2.2 Sample Preparation 56 3.2.3 Nuclear Magnetic Resonance (NMR) 56 3.2.4 Potentiodynamic Polarization 58 3.2.5 Exposure Experiments 59 3.3 Results 60 ix 3.3.1 Changes in Vanadate Speciation with pH Adjustment, Time, and Exposure to Aluminum 60 3.3.2 Soluble Inhibitor Release from Pigments 63 3.3.3 Aluminum 2024-T3 Aerated Polarization in NaCl Solutions 64 3.3.4 Aluminum 2024-T3 Deaerated Polarization in NaCl Solution 66 3.3.5 Corrosion Morphology of Aluminum in Vanadate Solution 67 3.4 Discussion 68 3.4.1 Speciation versus Corrosion Inhibition 68 3.4.2 Inhibition and Oxygen Dependence 70 3.4.3 Action of Vanadates on Al Alloy Surfaces 71 3.4.4 Vanadate Speciation and Vanadates in Hydrotalcite Pigments 72 3.5 Conclusions 73 4. ELECTROCHEMICAL EVALUATION OF CONSTITUENT INTERMETALLICS IN ALUMINUM ALLOY 2024-T3 EXPOSED TO AQUEOUS VANADATE INHIBITORS 98 4.1 Introduction 98 4.2 Experimental Procedures 103 4.2.1 Solution Preparation 103 4.2.2 Nuclear Magnetic Resonance (NMR) 104 4.2.3 Potentiodynamic Polarization Using the Microcapillary Electrode 105 4.2.4 Electrochemical Experiments on Bulk Al 2024-T3 Sheet 106 4.3 Results 108 x 4.3.1 Inhibition from Tetrahedral Vanadate Species vs. Octahedral Species 108 4.3.2 Tetrahedral Vanadate Species in Alkaline Electrolytes 109 4.3.3 Polarization of Intermetallics in Tetrahedral Vanadate Solutions 109 4.3.4 OCP and SEM Images of Al 2024 Exposed to Tetrahedral Vanadate Solution 113 4.3.5 Suppressed Al2CuMg Dissolution in Tetrahedral Vanadate Solutions 116 4.4 Discussion 117 4.4.1 Cathodic Inhibition from Tetrahedrally Coordinated Vanadate Species 117 4.4.2 Suppression of Al2CuMg Breakdown 118 4.4.3 Variation in Anodic Behavior of Al2CuMg 119 4.4.4 Vanadate Buffering and Circumferential Attack 120 4.5 Conclusions 122 5. HYDROTALCITE PIGMENTS FOR CORROSION INHIBITION OF ALUMINUM ALLOY 2024-T3 168 5.1 Introduction 168 5.2 Experimental Procedures 173 5.2.1 Materials and Chemicals 173 5.2.2 Hydrotalcite Pigment Synthesis 174 5.2.3 XRD Structure Confirmation 176 xi 5.2.4 Organic Coating Preparation and Application 176 5.2.5 Coating Evaluation by EIS on Panels Exposed to Static NaCl Solutions 177 5.2.6 Coating Evaluation by Salt Spray Exposure of Scribed Panels 177 5.2.7 Inhibitor Release Characterization Using NAA 178 5.3 Results 180 5.3.1 Structural Confirmation of Synthesized Pigments 180 5.3.2 EIS of PVB Coatings Pigmented with Vanadate Hydrotalcites 182 5.3.3 Salt Spray Exposure of Vanadate Hydrotalcite Pigmented Coatings 187 5.3.4 Inhibitor Release from Vanadate-Bearing Hydrotalcite Pigments 188 5.3.5 EIS of PVB Coatings Pigmented with Various Non Vanadate Hydrotalcites 190 5.3.6 Salt Spray Exposure of Non-Vanadate Hydrotalcite Pigmented Coatings and Controls 192 5.4 Discussion 192 5.4.1 Influence of Vanadate Speciation and Concentration on Vanadate Hydrotalcite Pigment Performance 192 5.4.2 Possible Influence of Cation Inhibitors Released into Solution 194 xii 5.4.3 Effect of Solubility on Vanadate Pigment Performance 195 5.4.4 Non-Vanadate Hydrotalcite Pigments Generally Do Not Provide Inhibition 196 5.5 Conclusions 196 6.
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