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  • 1.
    Eslami, M.
    et al.
    Univ Trento, Dept Ind Engn, Trento, Italy.
    Speranza, G.
    FBK, Ctr Mat & Microsyst, Trento, Italy.
    Deflorian, F.
    Univ Trento, Dept Ind Engn, Trento, Italy.
    Zanella, Caterina
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Polypyrrole coatings on rheocast aluminum-silicon alloy: A correlation between properties and electrodeposition conditions2019In: Surface and Interface Analysis, ISSN 0142-2421, E-ISSN 1096-9918Article in journal (Refereed)
    Abstract [en]

    The effect of the electrolyte composition and the deposition potential range on the physical properties and possible corrosion protection effect of polypyrrole coatings on rheocast aluminum–2.5 % silicon alloy is investigated. Solutions with different concentrations of sodium nitrate and an electron transfer mediator reagent were used for the electrodeposition. Polypyrrole coating is able to hinder the entrance of electrolyte. Upon the penetration of chloride ions, the coating can induce passivation of the alloy's surface by its reduction. The thickness of the coating and its ion-barrier properties, controlled by the electrodeposition conditions, are shown as the important factors influencing the protection efficiency. However, localized drastic galvanic coupling at the polypyrrole/aluminum interface forms blisters, causes failure, and limits the possible protection.

    The full text will be freely available from 2020-11-11 00:00
  • 2.
    Eslami, Maryam
    et al.
    Department of Industrial Engineering, University of Trento, Italy.
    Deflorian, Flavio
    Department of Industrial Engineering, University of Trento, Italy.
    Fedel, Michele
    Department of Industrial Engineering, University of Trento, Italy.
    Zanella, Caterina
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Ce-based conversion coatings on Rheo-HPDC low Si content aluminium alloy2017In: EUROCORR 2017 - The Annual Congress of the European Federation of Corrosion, 20th International Corrosion Congress and Process Safety Congress 2017, Asociace koroznich inzenyru z.s.- AKI - Czech Association of Corrosion Engineers , 2017, p. 777-794Conference paper (Refereed)
    Abstract [en]

    Cerium-based conversion coatings have been considered as an effective alternative to hazardous and carcinogenic chromate-based coatings used in the treatment of metal surfaces such as aluminium alloys. However, there is still considerable debate over the mechanism by which these coatings are formed on different alloys and microstructure features. In the current work, Ce-based conversion coatings were deposited on Rheo-HPDC Al-Si alloys by immersion in water-based solutions of cerium nitrate. Effect of deposition parameters including immersion time and Ce(NO3)3.6H2O concentration on the corrosion resistance and the morphology of coatings was investigated. In addition in some experiments, NaCl was added to the cerium based solution in order to accelerate the deposition of the conversion coating and also to understand the coating formation mechanism. Electrochemical behaviour of the treated aluminium alloys was evaluated in the solution of 0.05 mol/L NaCl using polarization test and electrochemical impedance spectroscopy (EIS) measurements. The morphology and distribution of the cerium-based conversion coatings on the aluminium alloys were studied using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDXS) and X-ray photoelectron spectroscopy (XPS). Conversion treated substrates in all solutions were shown to possess improved corrosion resistance in comparison to the untreated samples. Immersion time and Ce(NO3)3.6H2O concentration slightly affect the deposition and the passivation capability of the cerium hydroxide/oxide layers. SEM images revealed that the deposition of cerium is more favoured in some cathodic areas including iron-based intermetallics and/or eutectic silicon phase. This phenomenon helps to block the active interfaces between these cathodic sites and the aluminium matrix, which is prone to localized corrosion in chloride ion containing environments. 

  • 3.
    Eslami, Maryam
    et al.
    Department of Industrial Engineering, University of Trento, Trento, Italy.
    Deflorian, Flavio
    Department of Industrial Engineering, University of Trento, Trento, Italy.
    Zanella, Caterina
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Electrochemical performance of polypyrrole coatings electrodeposited on rheocast aluminum-silicon components2019In: Progress in organic coatings, ISSN 0300-9440, E-ISSN 1873-331X, Vol. 137, article id 105307Article in journal (Refereed)
    Abstract [en]

    Electropolymerization of polypyrrole coatings in the presence and absence of sodium nitrate was applied on rheo-cast Al-4.5% Si alloy and pure aluminum. The results showed that the eutectic silicon phase and intermetallic particles in the alloy's microstructure increase the electrodeposition rate in comparison to the pure aluminum substrate. The electrochemical and microstructural studies show that the polypyrrole coatings are able to protect the surface due to the barrier properties and the passivation protection provided by the reduction of the conductive polymer. The coating electrodeposited from sodium nitrate-containing electrolyte presented improved protection for longer immersion time. Localized formation of a thick oxide layer as a result of the drastic galvanic coupling at the polypyrrole/aluminum interface leads to blister formation and failure of the coating. It was revealed that the coating could be deposited into the porosities produced by the casting related defects, but in most cases, this affects the corrosion protection leading to imminent failure.

    The full text will be freely available from 2021-12-01 00:00
  • 4.
    Maryam, Eslami
    et al.
    University of Trento, Italy.
    Payandeh, Mostafa
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Deflorian, Flavio
    University of Trento, Italy.
    Jarfors, Anders E.W.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Zanella, Caterina
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Effect of Segregation and Surface Condition on Corrosion of Rheo-HPDC Al–Si Alloys2018In: Metals, Vol. 8, no 4, article id 209Article in journal (Refereed)
    Abstract [en]

    Corrosion properties of two Al–Si alloys processed by Rheo-high pressure die cast (HPDC) method were examined using polarization and electrochemical impedance spectroscopy (EIS) techniques on as-cast and ground surfaces. The effects of the silicon content, transverse and longitudinal macrosegregation on the corrosion resistance of the alloys were determined. Microstructural studies revealed that samples from different positions contain different fractions of solid and liquid parts of the initial slurry. Electrochemical behavior of as-cast, ground surface, and bulk material was shown to be different due to the presence of a segregated skin layer and surface quality.

  • 5.
    Zhu, Baiwei
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Fedel, Michele
    Department of Industrial Engineering, University of Trento, Trento, Italy.
    Andersson, Nils-Eric
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Leisner, Peter
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing. RISE Research Institute of Sweden, Borås, Sweden.
    Deflorian, Flavio
    Department of Industrial Engineering, University of Trento, Trento, Italy.
    Zanella, Caterina
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Influence of the Sr modification and post-treatment on corrosion resistance of oxide layer of cast Al-(low)Si alloys2017In: EUROCORR 2017 - The Annual Congress of the European Federation of Corrosion, 20th International Corrosion Congress and Process Safety Congress 2017, Asociace koroznich inzenyru z.s.- AKI - Czech Association of Corrosion Engineers , 2017, p. 27-39Conference paper (Refereed)
    Abstract [en]

    The current development of casting process makes it possible to cast low Si content aluminium alloys, which open the gate for the application of anodising on cast aluminium components. This paper aims to investigate the influence of Sr modification as well as the post-treatment on corrosion resistance of oxide layer of low Si content cast Al alloys. In the present study, designed Al-Si alloys with 5.45 wt-% Si were studied by performing electrochemical impedance spectroscopy (EIS) in 3 wt-% NaCl solution. The morphology of Si particle was determined by controlling the level of Sr. The microstructure features were evaluated by optical microscopy and scanning electron microscopy (SEM). Furthermore, focus ion beam-SEM (FIB-SEM) equipped with energy-dispersive X-ray spectroscopy (EDXS) was applied to exam the corrosion morphology and the anodised layer with Si rich eutectic phases. The EIS study revealed that the corrosion resistance of the oxide layer on cast Al alloys can be significantly influenced by the morphology of Si particle and the post-treatment. It was found that the change of Si particle morphology from flake-like to fibrous by Sr addition can substantially improve the corrosion resistance of the oxide layer in the unsealed condition due to the formation of the more compacted oxide layer with less defects. Normally, the application of a sealing step such as the hydrothermal sealing can improve the corrosion protection of the oxide layer. However, in the current study, it was found the hydrothermal sealing step leads to a significant reduce of the corrosion protection due to the generation of cracks into the oxide layer, and the hydrothermal sealing step can counteract the improvement of the corrosion protection by Sr addition.

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