Formation and function of chromate conversion coating on aircraft aluminum alloy probed by vibrational spectroscopy

A Chromate Conversion Coating (CCC) is currently one of the most effective methods for protecting aluminum alloys from corrosion. Its unique “self-healing” property has been proved to be critical in corrosion prevention. During the formation process, CrVI, is “stored” in the CCC films. Under in-field conditions, most of the CrVI can leach out and diffuse to local defects, and stop corrosion. However, the involvement of highly toxic CrVI makes CCC system environmentally hazardous. In order to find less-toxic alternatives, the formation and protection mechanisms of CCC must be understood. Formation and function of CCC film are the focus of this study, and vibrational spectroscopy was chosen due to its superior structural sensitivity. First, the structure of CCC film was characterized. The structural similarity between CCC film and a synthetic Cr-mixed-oxide was found, and certain tests were conducted on the bulk synthetic powder which were not feasible on the thin film. All of the structural studies indicated that CCC film is mainly a CrIII-hydroxide gel layer, which adsorbs CrVI-oxy species through CrIII-O-Cr VI chemical bonds. Further analysis revealed the reversible Cr III-CrVI adsorption-desorption equilibrium, and a mathematical model (“Langmuir” model) was established to explain the Cr VI storage-release mechanism quantitatively.; In addition, the function of Fe(CN)₆3−, an additive in the coating solution, was studied. The results indicate that Fe(CN)₆3− mediates the slow reaction between Al and CrVI, and the mediation mechanism can be illustrated as below: FeCN ^3- 6+Al=FeCN ^4-6+Al³⁺ ↑ FeCN ^4- 6+Cr^VI=FeCN ^3-6+Cr^III In general, the formation of CCC is mediated by Fe(CN)₆3−, thus Al reduces CrVI quickly and generates CrIII-hydroxide on the alloy surface. The nascent CrIII-hydroxide is chemically active enough to form chemical bonds with CrVI from the solution, through Cr III-O-CrVI bonding. Such CrIII-O-Cr VI structure can form and break up reversibly according to the Langmuir model, providing mobile CrVI for in-field protection.