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assigned to the stretching bands of the CH2 and CH3 corresponded to Si–OH bond; these absorption bands
groups respectively, and other vibration of group can be observed in all hybrid sol–gel coatings.
CH3 appeared at 2974 cm21. Vibrations at 1723 and
1637 cm21 corresponded to the C5O and C5C groups Pull-off tape adhesion test (ASTM D 3359-02)
respectively. The bands at 1079 cm21 are associated with The adhesion strength of PMMA–silica hybrid coatings
Si–O–Si linkages, and the bands at 950 and 879 cm21 on stainless steel was found to be higher than for pure
system PMMA coating alone, as evidenced by the
smaller stripped areas (Fig. 6). The adhesion of the
coating was further enhanced as the amount of TEOS
component was increased in the hybrid materials. It is
Electrochemical measurements
The results obtained with 5 wt-% NaCl solution after
visual evaluation analysis of the coated panels according
to ASTM D610 and ASTM D714 standards, are shown
in Tables 2 and 3 respectively. It is clear that the 50–50,
25–75 and 10–90 PMMA–silica hybrid coatings fail
before 1500 h exposure to the 5 wt-% NaCl solution,
while the 100–00 PMMA–silica hybrid coating fails after
1750 h exposure in the 5 wt-% NaCl solution, showing
both blistering and rusting. On the other hand, the other
systems (90–10 and 75–25 coatings) remain apparently
undamaged (neither blistering nor rusting was observed
7 Noise resistance Rn as function of exposure time in
on the other systems).
5 wt-% NaCl solution
The behaviour of the EN resistance Rn as a function
of exposure time to 5 wt-% NaCl solution for the
systems studied is shown in Fig. 7. For the 100–00 The 75–25 coating had higher Rn values than the pure
PMMA–silica system, which failed on visual inspection PMMA coating (100–00) during the whole immersion
after exposure for 1750 h, the initial Rn values were time, indicating the significant decrease in water uptake.
found to decrease by two orders of magnitude after only This behaviour may be caused by the hydrolysis reactions
250 h. It then increased to 500 h and declined again after of active alkoxy groups in 75–25 hybrid coating, by which
750 h, and then assumed very low values (105 V) beyond the free state water absorbed can be consumed. The
3000 h. This behaviour is probably due to the sealing of condensation reactions between the hydrolysed groups
pores by corrosion products (showing a clear tendency are also expected to improve the cross-linking of the
to decrease with time), which means that corrosion has hybrid coating. In addition, the hydrolysis products,
taken place at the metal/coating interface, in good methanol or ethanol, can also repel the permeation of
agreement with the visual evaluation previously water in the polymeric coatings, as reported by Flis and
reported. Thus, the initial barrier effect disappeared in Kanoza.32 The Rn behaviour of the 90–10 system can be
the 100–00 PMMA–silica system, while in the other attributed to the lower adhesion than that of the 75–25
systems (90–10 and 75–25), the effect was only system (see Fig. 6), while the Rn of the 50–50, 25–75 and
attenuated. With PMMA–silica coating system 90–10, 10–90 systems can be attributed to the lower barrier effect
the initial value of Rn decreased by one order of due to the reduced thickness of these coatings. It is
magnitude after 250 h, maintaining an average value important to mention that the preparation of thick sol–
of 106 V after 1750 h until the end of the test. The best gel ceramic coatings induces the formation of cracks
performance was for the 75–25 PMMA–silica system, during the drying procedure.33 For this reason, increasing
for which the initial Rn value decreased by half an order the thickness of the coatings 25–75 and 10–90 can lead to
of magnitude after 500 h. It then increased after 1000 h the appearance of defects due to high ceramic content;
and maintained an average value of 107 V until the end this is confirmed by the images in Fig. 3e and f.
of the test. It is interesting to study the shape and magnitude of
Figure 7 shows that the Rn values started to fall the current and potential noise transient signals. In
before visible corrosion was observed (in fact, 316L Figs. 8 and 9, the potential and current time series for
stainless steel had the lowest Rn since the start the test). the 100–00 and 75–25 systems at 0 h and after exposure
Table 3 Blistering degree (ASTM D714) after different
Table 2 Degree of rusting (ASTM D610) after different exposure times in 5 wt-% NaCl for 316L stainless
exposure times in 5 wt-% NaCl for 316L stainless steel panels covered with PMMA–silica hybrid
steel panels covered with PMMA–silica hybrid coatings*
coatings*
Immersion
316L time/h 100–00 90–10 75–25 50–50 25–75 10–90
Immersion 100– 90– 75– 50– 25– 10– stainless
time/h 00 10 25 50 75 90 steel 0 10 10 10 10 10 10
250 10 10 10 10 10 10
0 10 10 10 10 10 10 10 500 10 10 10 10 10 10
500 10 10 10 10 10 10 10 750 10 10 10 10 10 10
750 10 10 10 10 10 10 10 1000 10 10 10 10 10 10
1000 10 10 10 10 10 10 9 1250 10 10 10 10 8F 8F
1250 10 10 10 10 9 9 8 1500 10 10 10 8F 8F 8F
1500 10 10 10 9 8 8 7 1750 8F 10 10 8F 8F 8F
1750 9 10 10 8 8 7 7 2000 8F 8F 10 8M 6F 6F
2000 9 9 10 8 7 2250 8M 8F 10 6F 6F 6F
2250 9 8 10 8 7 2500 6F 8M 10 6F 6F 6F
2500 8 8 10 7 2750 6M 8M 10 6F 6F 6F
3000 8 8 9 7 3000 4M 6M 8F 6M 6F 6F
*10, 9: good coatings; 8, 7: bad coatings. *10: good coatings; 8, 6, 4: bad coatings.
for 1750 h to 5 wt-% NaCl solution are shown. This system are more noble at the beginning of the exposure
exposure time was selected for comparison because the [109–116 mV(SCE)]. For higher times of exposure
100–00 system failed after this interval. In Fig. 8a, it can (1750 h, Fig. 8c), the corrosion potential decreases to
be seen that the potential noise values for the 100–00 more active values [between 22 and 216 mV(SCE)].
Note that in this figure, the longer the exposure time, 6. J. Ballarre, D. A. López, N. C. Rosero, A. Durán, M. Aparicio and
S. M. Ceré: Surf. Coat. Technol., 2008, 203, 80–86.
(and consequently, the more degraded the coating), the
7. C. Martinez, M. Sancy, J. H. Zagal, F. M. Rabagliati, B. Tribollet,
lower the amplitude of the potential noise. For the 75–25 H. Torres, J. Pavez, A. Monsalve and M. A. Paez: J. Solid State
system (Fig. 9a), the potential noise values at the Electrochem., 2008, 13, 1327–1337.
beginning [123–130 mV(SCE)] and the potential noise 8. C. X. Li and T. Bell: Corros. Sci., 2006, 48, 2036–2049.
at 1750 h [between 49 and 54 mV(SCE)] are more noble 9. ‘Standard practice for surface preparation and marking of metallic
than the 100–00 system. surgical implants’, ASTM F-8604, ASTM International, West
Conshohocken, PA, USA, 2004.
For the current noise values, system 100–00 shows 10. ‘Standard specification for chemical passivation treatments for
signals that fluctuate more when the exposure time is stainless steel parts’, ASTM A967-01, ASTM International, West
longer. In addition, current noise values of 461027 Conshohocken, PA, USA, 2001.
mA cm22 were found during the stage of protection 11. K. Rose, S. Dzyadevych, R. Fernández-Lafuente, N. Jaffrezic,
(0 h) and between 2561027 and 161026 mA cm22 G. Kuncova, V. Mate and P. Scully: J. Coat. Technol. Res., 2008, 5,
491–496.
during the time of doubtful protection (1750 h), as shown 12. T. Sasaki and K. Kamitani: J. Sol–Gel Sci. Technol., 2008, 46, 180–
in Fig. 8b and d. Whereas for the system 75–25 (Fig. 9b), 189.
the initial current noise values were between 4 and 13. M. L. Zheludkevich, I. Miranda Salvado and M. G. S. Ferreira:
861027 mA cm22, while at 1750 h, they were between 1 J. Mater. Chem., 2005, 15, 5099–5111.
and 961027 mA cm22, showing better anticorrosive 14. T. P. Chou, C. Chandrasekaran, S. J. Limmer, C. Nguyen and
G. Z. Cao: J. Mater. Sci. Lett., 2002, 21, 251–255.
properties in good agreement with Fig. 7. 15. J. M. Yeh, C. J. Weng, W. J. Liao and Y. W. Mau: Surf. Coat.
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Conclusions 16. S. Ono, H. Tsuge, Y. Nishi and S. Hirano: J. Sol–Gel Sci. Technol.,
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The present work shows that by the sol–gel method, it is 17. J. Gallardo and P. Galliano: J. Sol–Gel Sci. Technol., 2001, 21, 65–
possible to synthesise PMMA–silica hybrid coatings 74.
with better corrosion resistance for 316L stainless steel 18. M. Zaharescu, L. Predoana, A. Barau, D. Raps, F. Gammel, N. C.
than that for neat polymer PMMA. The best antic- Rosero-Navarro, Y. Castro, A. Durán and M. Aparicio: Corros.
Sci., 2009, 51, 1998–2005.
orrosive properties were for the system with the ratio of 19. D. Raps, T. Hack, J. Wehr, M. L. Zheludkevich, A. C. Bastos,
75 : 25 PMMA/silica, which has the best performance M. G. S. Ferreira and O. Nuyken: Corros. Sci., 2009, 51, 1012–
as demonstrated by visual evaluation and EN. 1021.
Additionally, the excellent agreement between visual 20. M. Behzadnasaba, S. M. Mirabedinia, K. Kabiria and S. Jamalib:
evaluation analysis and EN confirms that the latter is a Corros. Sci., 2011, 53, 89–98.
21. N. C. Rosero-Navarro, S. A. Pellice, A. Durán and M. Aparicio:
useful tool for evaluating the anticorrosive performance Corros. Sci., 2008, 50, 1283–1291.
of coatings. These results also agree with the SEM 22. Y. Zhang, H. Ye, H. Liu and K. Han: Corros. Sci., 2011, 53, 1694–
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75–25 and 50–50 are continuous, crack free and well 23. N. P. Tavandashti, S. Sanjabi and T. Shahrabi: Prog. Org. Coat.,
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24. T. P. Chou, C. Chandrasekaran, S. J. Limmer, S. Seraji, Y. Wu,
One of the potential applications for such coatings may M. J. Forbess, C. Nguyen and G. Z. Cao: J. Non-Cryst. Solids,
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