Influence of pretreatment on corrosion behaviour of duplex zinc/polymer coatings on steel substrates

An investigation has been undertaken to determine the major factors influencing the corrosion resistance of duplex-zinc coatings on steel substrates.Premature failure of these systems has been attributed to the presence of defects such as craters and pinholes in the polymer film and debonding of the polymer film from the zinc substrate.Defects found on commercially produced samples have been carefully characterised using metallographic and scanning electron microscopy techniques. The influence of zinc substrate surface roughness, polymer film thickness and degassing of conversion coatings films on the incidence of defects has been determined.Pretreatments of the chromate, chromate-phosphate, non chromate, and alkali-oxide types were applied and the conversion coatings produced characterised with respect to their nature and composition. The effect of degassing on the properties of the films was also investigated. Electrochemical investigations were carried out to determine the effect of the presence of the eta or zeta phase as the outermost layer of the galvanized coating.Flow characteristics of polyester on zinc electroplated hot-dip continuous and batch galvanized and zinc sprayed samples were investigated using hot-stage microscopy. The effects of different pretreatments and degassing after conversion coating formation on flow characteristics were determined.Duplex coatings were subjected to the acetic acid salt spray test. The effect on adhesion was determined using an indentation debonding test and the results compared with those obtained using cross-cut/peel and pull-off tests. The locus of failure was determined using scanning electron microscopy and X-ray photoelectron spectroscopy techniques.

Powder painting of aluminium

The mechanisms involved in the production of chromate-phosphate conversion coatings on aluminium have been investigated. A sequence of coating nucleation and growth has been outlined and the principle roles of the constituent ingredients of the chromate-phosphate solution have been shown. The effect of dissolved aluminium has been studied and its role in producing sound conversion coatings has been shown. Metallic contamination has been found to have a dramatic influence on chromate-phosphate coatings when particular levels have been exceeded. Coating formation was seen to be affected in proportion to the level of contaminaton; no evidence of sudden failure was noted. The influence of substrate and the effect of an acidic cleaner prior to conversion coating have been studied and explained. It was found that the cleaner ages rapidly and that this must .be allowed for when attempting to reproduce industrial conditions in the laboratory. A study was carried out on the flowing characteristics of polyester powders of various size distributions as they melt using the hot-stage microscopy techniques developed at Aston. It was found that the condition of the substrate (ie extent of pretreatment), had a significant effect on particle flow. This was explained by considering the topography of the substrate surface. A number of 'low-bake' polyester powders were developed and tested for mechanical, physical and chemical resistance. The best formulation had overall properties which were as good as the standard polyester in many respects. However chemical resistance was found to be slightly lower. The charging characteristics of powder paints during application by means of electrostatic spraying was studied by measuring the charge per unit mass and relating this to the surface area. A high degree of correlation was found between charge carried and surface area, and the charge retained was related to the powder's formulation.

Investigating the role of cholesterol in the formation of non-ionic surfactant based bilayer vesicles:thermal analysis and molecular dynamics

The aim of this research was to investigate the molecular interactions occurring in the formulation of non-ionic surfactant based vesicles composed monopalmitoyl glycerol (MPG), cholesterol (Chol) and dicetyl phosphate (DCP). In the formulation of these vesicles, the thermodynamic attributes and surfactant interactions based on molecular dynamics, Langmuir monolayer studies, differential scanning calorimetry (DSC), hot stage microscopy and thermogravimetric analysis (TGA) were investigated. Initially the melting points of the components individually, and combined at a 5:4:1 MPG:Chol:DCP weight ratio, were investigated; the results show that lower (90 C) than previously reported (120-140 C) temperatures could be adopted to produce molten surfactants for the production of niosomes. This was advantageous for surfactant stability; whilst TGA studies show that the individual components were stable to above 200 C, the 5:4:1 MPG:Chol:DCP mixture show ∼2% surfactant degradation at 140 C, compared to 0.01% was measured at 90 C. Niosomes formed at this lower temperature offered comparable characteristics to vesicles prepared using higher temperatures commonly reported in literature. In the formation of niosome vesicles, cholesterol also played a key role. Langmuir monolayer studies demonstrated that intercalation of cholesterol in the monolayer did not occur in the MPG:Chol:DCP (5:4:1 weight ratio) mixture. This suggests cholesterol may support bilayer assembly, with molecular simulation studies also demonstrating that vesicles cannot be built without the addition of cholesterol, with higher concentrations of cholesterol (5:4:1 vs 5:2:1, MPG:Chol:DCP) decreasing the time required for niosome assembly. © 2013 Elsevier B.V.