Preparation and Applications of Superhydrophobic Coatings on Aluminum Alloy Surface for Anti-Corrosion and Anti-Fouling: A Mini Review
Abstract
:1. Introduction
2. Coating Types on the Surface of Aluminum Alloy for Anti-Corrosion and Anti-Fouling
2.1. Chemical Conversion Film Coatings
2.2. Anodizing Film Coatings
2.3. Organic Painting Coatings
2.4. Superhydrophobic Coatings
3. Preparation Methods for Superhydrophobic Coating on the Surface of Aluminum Alloy for Anti-Corrosion and Anti-Fouling
3.1. Impregnation Method
3.2. Spraying Method
3.3. Anodization Method
3.4. Plasma Electrolytic Oxidation Method
3.5. Electrodeposition Method
3.6. Other Methods
4. Application of Superhydrophobic Coating on the Surface of Aluminum Alloy for Anti-Corrosion and Anti-Fouling
4.1. Application Status and Problems of Superhydrophobic Coating on Aluminum Alloy Surface for Anti-Corrosion and Anti-Fouling
4.2. Methods for Improving the Performance of Superhydrophobic Coating on the Surface of Aluminum Alloy for Anti-Corrosion and Anti-Fouling
4.2.1. Improve the Preparation Process of Superhydrophobic Coating on the Surface of Aluminum Alloy
4.2.2. Preparation of Superhydrophobic Coatings with Self-Healing Properties
4.2.3. Introduction of Buffer or Sacrificial Layer into a Superhydrophobic Coating
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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The types of Coatings | Characteristics | Advantages | Drawbacks | References |
---|---|---|---|---|
Chemical Conversion Film Coatings | A few micrometers in thickness As a connecting layer between the topcoat and the aluminum alloy substrate, it increases the adhesion of the coating. | Low cost Simple production process Wear resistant Good corrosion resistance Suitable for large-scale industrialization | Cr (VI) is poisonous and carcinogenic. Phosphorus-containing wastewater could cause eutrophication of water bodies. | [11,12,13,14,15,16,17,18,19,20,21,22,23,24,25] |
Anodizing Film Coatings | Thickness in micrometers Composed of alumina in the shape of nano-channels Post-treatment for sealing holes or use with coatings. | Good adhesion on the substrate Suitable for large-scale industrialization | Once the coating is damaged, the substrate is corroded | [26,27,28,29,30,31] |
Organic Painting Coatings | Consists of three layers, with the layer in contact with the aluminum alloy being a priming coat, the top layer being a topcoat, and the intermediate coat connecting the priming coat and topcoat. Suitable for substrates of any size and shape. | Good weather resistance Anti-fouling and preventing adhesion of marine organisms Suitable for large-scale industrialization | It may degrade in aqueous solution. Environmentally unfriendly Poor adhesion on the substrate | [32,33,34,35,36,37,38,39,40,41,42,43,44,45,46] |
Superhydrophobic coatings | Non-infiltration. Synergistic effect of micro-nano graded rough structure and low surface energy material modification. | Good anti-corrosion and anti-fouling Self-healing | Poor chemical stability Poor durability | [7,8,47,48,49,50,51] |
Al alloy Type | Preparation Method | Coating Composition | The Performance of the Coating | References | |||
---|---|---|---|---|---|---|---|
Water Contact Angle (WCA) | Sliding Angle (SA) | Ecorr (V) | Icorr (A·cm−2) | ||||
6061 | Hydrothermal method + impregnation modification | Ni-Al LDHs, Stearic acid (SA) | 162.1 ± 0.4° | 1.9 ± 0.3° | −0.28 | 2.88 × 10−8 | [70] |
4037 | Hydrothermal method + impregnation modification | ZnO, Poly-dimethyl-siloxane (PDMS) | 161.1° | 3.3° | −0.59 | 8.12 × 10−8 | [71] |
6061 | Hydrothermal method + impregnation modification | Mg-Al LDHs, Triethoxy-1H,1H,2H,2H-trideca-fluoro-n-octylsilane (FAS-13) | 160° | −0.33 | 7.94 × 10−6 | [72] | |
3003 | Hydrothermal method+ impregnation modification | Zn-Al LDHs, Cetyl trimethoxy-silane, hexadecyl-trimethoxy-silane | 156.3° | −0.66 | 3.87 × 10−8 | [73] | |
6061 | Hydrothermal method | Zn-Al LDHs, Sodium dodecyl sulfate (SDS) | 161° | −0.26 | 2.01 × 10−8 | [74] | |
6020 | Shot peening + chemical etching + impregnation modification | Methyl trichlorosilane (MTCS) | 153 ± 2° | 8 ± 2° | [10] | ||
5083 | Thermo-mechanical and microwave-assisted hydrothermal processing+ Chemical vapor deposition | 1H,1H,2H,2H-Perfluorooctyltrieth-oxysilane (FOTES) | 162 ± 1° | 1 ± 2° | [77] | ||
6061 | Coating method+ Ultrasonic spray hydrolysis deposition | Polyvinylidene fluoride (PVDF), hydrolyzed methyl-trimethoxy-silane (HMTMS) | 167° | 7 ± 1° | −0.61 | 2.87 × 10−8 | [78] |
6061 | Anodization + sealing treatment+ impregnation modification | TiO2 nanoparticles, Octadecyl trimethoxy-silane (OTS) | 154.2 ± 1.7° | 8° | −0.348 | 4.78 × 10−11 | [59] |
2024 | Anodization + spraying | Triethoxy-silane containing ZnO nanoparticles | 151.2° | 7° | −0.503 | 3.79 × 10−6 | [79] |
Pure Al | Plasma electrolytic oxidation+ electrodeposition | Al2O3, Cerium hexa-decylate | 165.5° | 5.2° | −0.73 | 1.8 × 10−7 | [80] |
6061 | Electrodeposition | Cobalt stearate | 161 ± 1° | 2° | −0.706 | 0.8 × 10−8 | [66] |
Pure Al | Two-step electrodeposition | SiC particles, Cetyl-trimethyl-cerium, Palmitic acid | 162.3° | 1.5° | −0.755 | 5.224 × 10−9 | [81] |
6063 | water treatment + impregnation modification | Stearic acid | 154.1° | −0.96 | 5.01 × 10−5 | [82] | |
5052 | chemical etching + Deposition + impregnation modification | Zn-Al LDH, Stearic acid | 164 ± 3° | 1 ± 0.5° | 0.49 | 3.5 × 10−7 | [83] |
Pure Al | laser etching+ impregnation modification | 1H,1H,2H,2H- Perfluoro-octane triethoxy-silane (PFOTES) | 152.8° | 0.6° | [84] | ||
Al-Si alloy | Sol-gel process | Heptadecafluoro-1,1,2,2-tetrahydrodecyl trichlorosilane (HDFS) | 166.04° | 8.86° | [75] | ||
2024-T3 | Spraying | SiO2 nanoparticles, Dodecyl-trimethoxy-silane, Epoxy resin | 165° | ≈0° | −0.63 | 2.66 × 10−9 | [85] |
Preparation Method | Advantages | Disadvantages | References |
---|---|---|---|
Spraying | Simple one-step preparation; Low cost; Large-scale preparation. | The adhesion of the coating is low, and it is easy to fail after being damaged by external forces, resulting in unsatisfactory durability. Organic coatings are potentially harmful to humans and the environment. | [86,87,88,89] |
Impregnation | Simple and economical; Suitable for large-scale preparation; Suitable for surfaces of all shapes or sizes; Able to realize one-step preparation. | The uniformity of the coating is uncontrollable; The adhesion of the coating to the substrate is poor, and it is easy to fall off. The use of fluorine-containing organic reagents contradicts environmental protection. | [7,76,90,91] |
Anodization | Low cost and simple and fast manufacturing; Precise control of surface roughness and nanostructure; Better adhesion to substrates; Not prone to aging and wear. | The prepared film layer has pores; subsequent pore-sealing treatment or modification of low surface energy substances is required. Obtaining a relatively uniform coating is challenging. | [92,93,94] |
Electrodeposition | Easy control of coating topography and thickness; The process is relatively simple; Suitable for industrial-scale production; Environmentally friendly; Able to realize one-step preparation. | Limited cathode metal area leads to low preparation efficiency; low surface energy substances in the electrolyte are not used efficiently; The coating adhesion is poor, and the surface is easy to wear. | [95,96,97] |
Chemical etching | The preparation process is simple; Low cost; Able to precisely select the processing area. | The micro-nanostructure of the coating is not easy to control; The solutions or by-products used are not environmentally friendly; Subsequent modification of low surface energy substances is required. | [52,98,99] |
Laser etching | It is possible to obtain regular and controllable micro-nano structures; The preparation process is environmentally friendly. | Special equipment is required; it is Costly. Subsequent modification with low surface energy substances is needed. | [84,92,100] |
Hydrothermal method | The microscopic size of the coating is relatively uniform; Able to realize one-step preparation. | High temperature and high-pressure conditions are required; High requirements for preparation equipment. | [8,101,102] |
Sol-gel process | High temperature and pressure conditions are not required; Suitable for surfaces of different shapes or sizes. | There is thermal cracking behavior, Inaccurate coating thickness, and Expensive and environmentally unfriendly. | [7,75,76,103] |
The Primary Preparation Process of the Coating | Chemical Stability | Mechanical Durability | References |
---|---|---|---|
Sodium hydroxide etching; Lauric acid impregnation modification | WCA dropped to 125.3° after immersion in 5% acetic acid solution for 6 days. | The peel test was carried out with 100 N/m insulation tape, and the coating lost its superhydrophobicity after 15 viscous peels. | [55] |
Hydrochloric acid etching; Deposition of Zn-Al LDH film; Stearic acid impregnation modification. | Lost superhydrophobicity after 7 days of immersion in 0.6 mol/L NaCl solution; Lost superhydrophobicity after 14 days of immersion in distilled water. | Using 1500 mesh SiC abrasive paper, the coating lost its superhydrophobicity after applying 2 N pressure friction for 250 cm. | [83] |
Anodizing; electrodeposited TiO2 nanoparticles; Octadecyl trimethoxy-silane impregnation modification | WCA dropped to 141.8° and lost superhydrophobicity after 7 days of immersion in seawater. | [112] | |
Anodizing; Lauric acid impregnation modification. | Using 2000 mesh SiC sandpaper load 100 g for uniform friction, lost superhydrophobicity when the wear distance is 300 cm. | [58] | |
Scrub treatment; Hydrochloric acid etching; Stearic acid impregnation modification. | Lost superhydrophobicity after 14 days of immersion in NaCl solution (0.6 mol/L). | [113] | |
High-speed wire discharge machining; Hydrochloric acid etching; Perfluorooctanoic acid impregnation modification | Lost its superhydrophobicity after rubbing the sample for 260 cm at 20 kPa using 1000 sand-grained sandpaper. Using a 200 g weight drop from a height of 12 cm and hitting the coatings directly at approximately 15.50 cm/s, it lost superhydrophobicity after 35 times. | [114] | |
Hydrochloric acid etching; Stearic acid impregnation modification. | After 1 day of immersion in 3.5 wt% NaCl solution, WCA < 150°. Lost superhydrophobicity after a 14-h salt spray test. | [115] | |
Laser etching; 1H, 1H, 2H, 2H- Perfluoro-octyl-triethoxy-silane impregnation modification. | The coating lost superhydrophobicity after rubbing 150 cm with a 1000 mesh sandpaper load of 200 g. | [84] | |
Spray nano-SiO2 particles and 1H, 1H, 2H, 2H-perfluorodialkyltriethoxysilane modified epoxy resins. | A peel test was performed using 3 M VHB tape, and the coating lost superhydrophobicity at the 40 th peel. The coating lost its superhydrophobicity after wearing 900 cm with a 2000 mesh sandpaper load of 100 g. | [116] | |
Spray polystyrene microspheres and polydimethylsiloxane. | Heated at 260 °C for 1 h, the coating lost its superhydrophobicity. | [56] | |
Spray F-SiO2 nanoparticles, epoxy resin, fluoro-silicone paint, and fluorinated polyurethane. | 50 μL of water is used for dripping onto the surface of the coating at a rate of 160 drops per minute from a height of 40 cm, and the coating lost its superhydrophobicity after 2 h. | [57] | |
Spray SiO2 nanoparticles and epoxy resins modified with dodecyl-trimethoxy-silane. | After 40 h of irradiation under ultraviolet light, the WCA of the coating drops to 149.3°, while after 12 h of irradiation, the SA of the coating increases to 15.7°. | [85] | |
Plasma oxidation; Chemical vapor deposition of fluorinated SiO2 nanoparticles. | After 9 days of immersion in 3.5 wt% NaCl solution, the coating lost its superhydrophobicity. | After peeling off 20 cycles with 3 M tape, the coating lost its superhydrophobicity. | [62] |
One-step electrodeposition of Iron (III) chloride hexahydrate and myristic acid. | After rubbing at a constant speed of 60 cm with a load of 40 g using 240 mesh sandpaper, the coating lost its superhydrophobicity. | [69] | |
Thermomechanical and microwave-assisted hydrothermal treatment; Chemical vapor deposition perfluoro-octyl-triethoxy-silane. | After 6 days of immersion in 3.5 wt% NaCl solution, the coating lost its superhydrophobicity. | [77] | |
Electrodeposition of SiC particles, trimethyl cerium palmitate, and palmitic acid first; then electrodeposition of palmitic acid. | After 9 days of immersion in 3.5 wt% NaCl solution, the WCA of the coating decreases to 147.5°, while on day 8, the SA of the coating increases to 10.5°. | After rubbing 300 cm with a 50 g weight load of 1000 mesh sandpaper, the WCA of the coating is reduced to 135.4°. A 2 kg steel rod is rolled over the specimen surface, and the coating loses its superhydrophobicity after 18 cycles. | [81] |
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Zhu, Q.; Du, X.; Liu, Y.; Fang, X.; Chen, D.; Zhang, Z. Preparation and Applications of Superhydrophobic Coatings on Aluminum Alloy Surface for Anti-Corrosion and Anti-Fouling: A Mini Review. Coatings 2023, 13, 1881. https://doi.org/10.3390/coatings13111881
Zhu Q, Du X, Liu Y, Fang X, Chen D, Zhang Z. Preparation and Applications of Superhydrophobic Coatings on Aluminum Alloy Surface for Anti-Corrosion and Anti-Fouling: A Mini Review. Coatings. 2023; 13(11):1881. https://doi.org/10.3390/coatings13111881
Chicago/Turabian StyleZhu, Qianyi, Xiaoqing Du, Yudie Liu, Xuming Fang, Dongchu Chen, and Zhao Zhang. 2023. "Preparation and Applications of Superhydrophobic Coatings on Aluminum Alloy Surface for Anti-Corrosion and Anti-Fouling: A Mini Review" Coatings 13, no. 11: 1881. https://doi.org/10.3390/coatings13111881