| Summary: | This study deals with the combination of two corrosion protection strategies for aluminium: barrier protection (provided by a 3.8 μm thick hybrid sol–gel coating) and aluminium pore sealing via the use of a 100 nm thick layer of aluminium oxide. A Si–O–Zr hybrid sol–gel coating (TMZ) was synthesised by combining two separately prepared sols (i) tetraethyl orthosilicate and 3-methacryloxypropyl trimethoxysilane and (ii) zirconium(IV) n-propoxide chelated with methacrylic acid. The synthesis of the Si–O–Zr hybrid sol–gel was evaluated at various stages using real-time infrared spectroscopy. A 100 nm thick Al<sub>2</sub>O<sub>3</sub> film was prepared via thermal atomic layer deposition at 160 °C using trimethyl aluminium and water as precursors. The coating and film properties were assessed via focused ion beam/scanning electron microscopy coupled with energy-dispersive X-ray spectrometry. Sealing with the Al<sub>2</sub>O<sub>3</sub> film did not affect the microstructure and composition of the underlying sol–gel coating. The coating’s corrosion performance in 0.1 M NaCl solution was evaluated using electrochemical impedance spectroscopy. Compared to individual coatings, the multilayer TMZ/Al<sub>2</sub>O<sub>3</sub> coating ensured prolonged (more than three weeks) durable corrosion protection for the aluminium. The impedance magnitude increased by two orders compared to the uncoated substrate (|Z|<sub>10 mHz</sub> from 16 kΩ cm<sup>2</sup> to almost 830 MΩ cm<sup>2</sup>). Thus, the pore sealing of the sol–gel coating using an ALD alumina film produced a protective multilayer coating system, with |Z|<sub>10 mHz</sub> remaining above 5 MΩ cm<sup>2</sup> after four weeks in NaCl solution.
|
|---|