Corrosion inhibition by inorganic cationic inhibitors on the high strength alumunium alloy, 2024-T3

The toxicity and carcinogenic nature of chromates has led to the investigation of environmentally friendly compounds that offer good corrosion resistance to AA 2024-T3. Among the candidate inhibitors are rare earth metal cationic (REM) and zinc compounds, which have received much of attention over the past two decades. A comparative study on the corrosion inhibition caused by rare earth metal cations, Ce3+, Pr3+, La3+ and Zn2+ cations on the alloy was done. Cathodic polarization showed that these inhibitor ions suppress the oxygen reduction reaction (ORR) to varying extents with Zn2+ providing the best inhibition. Pr3+ exhibited windows of concentration (100-300 ppm) in which the corrosion rate is minimum; similar to the Ce3+ cation. Scanning Electron Microscopy (SEM) studies showed that the mechanism of inhibition of the Pr3+ ion is also similar to that of the Ce3+ ion. Potentiodynamic polarization experiments after 30 min immersion time showed greatest suppression of oxygen reduction reaction in neutral chloride solutions (pH 7), which reached a maximum at a Zn2+ ion concentration of 5 mM. Anodic polarization experiments after 30 min immersion time, showed no anodic inhibition by the inhibitor in any concentration (0.1 mM -- 10 mM) and at any pH. However, anodic polarization of samples immersed after longer immersion times (upto 4 days) in mildly acidic Zn2+ (pH 4) solutions showed significant reduction in anodic kinetics indicating that zinc also acts as a "slow anodic inhibitor". In contrast to the polarization experiments, coupons exposed to inhibited acidic solutions at pH 4 showed complete suppression of dissolution of Al2CuMg particles compared to zinc-free solutions in the SEM studies. Samples exposed in pH 4 Zn2+-bearing solution exhibited highest polarization resistance which was also observed to increase with time. In deaerated solutions, the inhibition by Zn2+ at pH 4 is not observed as strongly. The ability to make the interfacial electrolyte alkaline is retarded in the absence of oxygen. As a result precipitation of Zn oxides and hydroxides was suppressed. Impedance in decarbonated chloride solutions showed that the absence of CO 2 reduces inhibition by Zn2+ at pH 4. The carbonate protective layer formed in aerated solutions is essential for providing better protection of the substrate at pH 4.;Inhibitor cations were exchanged into insoluble ion-exchanging sodium bentonites and incorporated as pigments in organic coatings applied to AA 2024-T3 substrates. XRD of the pigments ensured ion exchange and UV-visible spectroscopy was used to characterize inhibitor ion release from the bentonites. Salt spray exposure tests on scribed panels were preformed and results were compared to those from SrCrO4 pigmented coatings. Zn-exchanged bentonite pigmented coatings showed better performance compared to the other exchanged bentonites when incorporated into epoxy coatings with total impedance magnitude in the same order as SrCrO4. PVB (Polyvinyl Butyral) coatings containing Zn bentonite, however, did not show superior behaviour in the impedance response due to less or no water uptake. Salt spray exposures for a period of 336 h, showed that Zn bentonite incorporated into PVB suppressed blistering compared to the neat PVB and other pigmented bentonites.