Improved corrosion protection of aluminum alloys by low-temperature plasma interface engineering

The System Approach Interface Engineering (SAIE) concept was employed to develop corrosion protection processes for aluminum (Al) alloys by application of a low temperature plasma interface engineering technique with a cathodic electrocoat (E-coat) as the primary layer coating. The SAIE concept emphasizes that the corrosion protection property of the coated system for Al alloys depends on the total system rather than any good corrosion protection component of the system.; The cathodic E-coated SAIE plasma pretreatments on Alclad 2024-T3, 2024-T3 bare and 7075-T6 bare alloys showed excellent corrosion resistance property when tested by SO2 and Prohesion salt spray tests. These systems out performed the conventional conversion coated controls, chromate conversion coated then Deft primer coated (CC Deft) and chromate conversion coated then cathodic E-coated (CC E-coat) in both the corrosion testes. The corrosion protection by SAIE systems depends on three major factors; (1) improved barrier characteristics of E-coat, (2) water insensitive adhesion of E-coat to plasma polymers deposited in a DC discharge and (3) creating a stable surface oxide layer by plasma treatment or chemical cleaning.; Different chemical pretreatments were employed to create a stable barrier type aluminum oxide layer on the surfaces of the substrates prior to plasma polymer deposition. The surface analysis showed that these pretreatments depend on the type of alloy and surface chemistry. As received surfaces with acetone wipe and plasma cleaning of the organic contaminants was found to be best for Alclad 2024-T3 alloy. Chemical alkaline cleaning for 2024-T3 bare and alkaline cleaning followed by deoxidization for 7075-T6 bare alloy were necessary.; The adhesion of the cathodic E-coat was improved by surface energy matching techniques by deposition of various plasma polymer films of trimethylsilane (TMS) and mixtures of TMS with O2, H2, and N2. The adhesion performance evaluated by the N-methylpyrrolidinone (NMP) test method showed that the low temperature plasma interface engineering technique could be used to create adhesion performance range for the organic paint on the metal surfaces from easily removable to coatings for life.; The barrier properties of the cathodic E-coat were improved by the plasma polymer deposition on which E-coat was applied.