Skip to main content
SpringerLink
Log in

Effect on the corrosion resistance property of aluminum substrate by altering the wetting behavior

  • Published:
Journal of Coatings Technology and Research Aims and scope Submit manuscript

Abstract

For engineering systems like vehicles, pipelines, aircraft, and ships, corrosion in aluminum metal is a serious operational and financial challenge. In this paper, a facile and effective strategy was applied to develop superhydrophilic, hydrophilic (inherent nature), hydrophobic, and superhydrophobic surfaces via the different surface treatments. Superhydrophobic surfaces were fabricated at different roughness scales using three different acidic etchants, namely, hydrochloric acid (HCl), hydrochloric acid and nitric acid (HCl + HNO3), and hydrochloric acid and cupric chloride dihydrate (HCl + CuCl2.2H2O) followed by the low surface energy material (hexadecyltrimethoxysilane). Then, the corrosion behavior of the different surfaces was assessed. The surface treatment and coating deposition characterizations of the samples were investigated by surface morphology, surface roughness, and wettability measurements. Each sample displayed distinct water contact and sliding angles based on its surface treatment. Additionally, an effect on the corrosion property of uncoated and all treated samples was studied in detail by electrochemical impedance spectroscopy. The results demonstrated that superhydrophobic and hydrophobic surfaces could improve corrosion resistance compared to uncoated aluminum.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

References

  1. Heinz, A, Haszler, A, Keidel, C, Moldenhauer, S, Benedictus, R, Miller, WS, “Recent Development in Aluminium Alloys for Aerospace Applications.” Mater. Sci. Eng. A, 280 102–107 (2000)

    Article  Google Scholar 

  2. Genzer, J, Efimenko, K, “Recent Developments in Superhydrophobic Surfaces and Their Relevance to Marine Fouling: A Review.” Biofouling, 22 339–360 (2006)

    Article  CAS  Google Scholar 

  3. Kumar, S, “Overview of Corrosion and its Control: A Critical Review.” Proc. Eng. Sci., 3 13–24 (2021)

    Google Scholar 

  4. Bhushan, B, Biomimetic: Bioinspired Hierarchical-Structured Surfaces for Green Science and Technology, 3rd edn. Springer, Cham (2018)

    Book  Google Scholar 

  5. Paras Kumar, A, “Smart Bioinspired Anti-wetted Surfaces: Perspectives, Fabrication, Stability and Applications.” Curr. Res. Green Sustain. Chem., 4 100139 (2021)

    Article  Google Scholar 

  6. Moghadam, SG, Parsimehr, H, Ehsani, A, “Multifunctional Superhydrophobic Surfaces.” Adv. Colloid Interf. Sci., 290 102397 (2021)

    Article  Google Scholar 

  7. Zhang, W, Wang, D, Sun, Z, Song, J, Deng, X, “Robust Superhydrophobicity: Mechanisms and Strategies.” Chem. Soc. Rev., 50 4031–4061 (2021)

    Article  CAS  Google Scholar 

  8. Sataeva, NE, Boinovich, LB, Emelyanenko, KA, Domantovsky, AG, Emelyanenko, AM, “Laser-Assisted Processing of Aluminum Alloy for the Fabrication of Superhydrophobic Coatings Withstanding Multiple Degradation Factors.” Surf. Coat. Technol., 397 25993 (2020)

    Article  Google Scholar 

  9. Liu, J, Fang, X, Zhu, C, Xing, X, Cui, G, Li, Z, “Fabrication of Superhydrophobic Coatings for Corrosion Protection by Electrodeposition: A Comprehensive Review.” Coll. Surf. A Physicochem. Eng. Asp., 607 125498 (2020)

    Article  CAS  Google Scholar 

  10. Barati, G, Aliofkhazraei, M, Khorsand, S, Sokhanvar, S, Kaboli, A, “Science and Engineering of Superhydrophobic Surfaces: Review of Corrosion Resistance, Chemical and Mechanical Stability.” Arab. J. Chem., 13 1763–1802 (2020)

    Article  Google Scholar 

  11. Zhang, D, Wang, L, Qian, H, Li, X, “Superhydrophobic Surfaces for Corrosion Protection: A Review of Recent Progresses and Future Directions.” J. Coat. Technol. Res., 13 11–29 (2016)

    Article  Google Scholar 

  12. Simpson, JT, Hunter, SR, Aytug, T, “Superhydrophobic Materials and Coatings: A Review.” Rep. Prog. Phys., 78 (8) 086501 (2015)

    Article  Google Scholar 

  13. Varshney, P, Lomga, J, Gupta, PK, Mohapatra, SS, Kumar, A, “Durable and Regenerable Superhydrophobic Coatings for Aluminium Surfaces with Excellent Self-Cleaning and Anti-Fogging Properties.” Tribol. Int., 119 (38) 44 (2017)

    Google Scholar 

  14. Zhu, P, Zhu, L, Ge, F, Wang, G, Zeng, Z, “Sprayable Superhydrophobic Coating with High Mechanical/Chemical Robustness and Anti-corrosion.” Surf. Coat. Technol., 443 128609 (2022)

    Article  CAS  Google Scholar 

  15. Rodic, P, Kapun, B, Panjan, M, Milosev, I, “Easy and Fast Fabrication of Self-Cleaning and Anti-icing Perfluoroalkyl Silane Film on Aluminium.” Coatings, 10 6–9 (2020)

    Article  Google Scholar 

  16. Kumar, A, Gogoi, B, “Development of Durable Self-cleaning Superhydrophobic Coatings for Aluminium Surfaces via Chemical Etching Method.” Tribol. Int., 122 114–118 (2018)

    Article  CAS  Google Scholar 

  17. Feng, L, Zhang, H, Wang, Z, Liu, Y, “Superhydrophobic Aluminum Alloy Surface: Fabrication, Structure, and Corrosion Resistance.” Coll. Surf. A Physicochem. Eng. Asp., 441 319–325 (2014)

    Article  CAS  Google Scholar 

  18. Varshney, P, Mohapatra, SS, Kumar, A, “Fabrication of Mechanically Stable Superhydrophobic Aluminium Surface with Excellent Self-Cleaning and Anti-Fogging Properties.” Biomimetics, 2 1–23 (2017)

    Article  Google Scholar 

  19. Lomga, J, Varshney, P, Nanda, D, Satapathy, M, Mohapatra, SS, Kumar, A, “Fabrication of Durable and Regenerable Superhydrophobic Coatings with Excellent Self-cleaning and Anti-fogging Properties for Aluminium Surfaces.” J. Alloys Compd., 702 (161) 170 (2017)

    Google Scholar 

  20. Boinovich, LB, Emelyanenko, AM, “Hydrophobic Materials and Coatings: Principles of Design, Properties and Applications.” Russ. Chem. Rev., 77 (583) 600 (2008)

    Google Scholar 

  21. Wenzel, RN, “Resistance of Solid Surfaces to Wetting by Water.” Ind. Eng. Chem., 28 988–994 (1936)

    Article  CAS  Google Scholar 

  22. Cassie, BD, “Wettability of Porous Surfaces.” Trans. Faraday Soc., 40 546–551 (1944)

    Article  CAS  Google Scholar 

  23. Liao, R, Zuo, Z, Guo, C, Yuan, Y, Zhuang, A, “Fabrication of Superhydrophobic Surface on Aluminum by Continuous Chemical Etching and Its Anti-icing Property.” Appl. Surf. Sci., 317 701–709 (2014)

    Article  CAS  Google Scholar 

  24. Ulman, A, “Formation and Structure of Self-assembled Monolayers.” Chem. Rev., 96 1533–1554 (1996)

    Article  CAS  Google Scholar 

  25. Attar, MR, Khajavian, E, Hosseinpour, S, Davoodi, A, “Fabrication of Micro–Nano-Roughened Surface with Superhydrophobic Character on an Aluminium Alloy Surface by a Facile Chemical Etching Process.” Bull. Mater. Sci., 43 1–8 (2020)

    Article  Google Scholar 

  26. Ma, X, Wang, Y, Wu, H, Wang, Y, Yang, Y, “Efficient Water Scavenging by Cooling Superhydrophobic Surfaces to Obtain Jumping Water Droplets from Air.” Sci. Rep., 9 1–7 (2019)

    Google Scholar 

  27. Oh, HJ, Lee, JH, Ahn, HJ, Jeong, Y, Park, NJ, Kim, SS, Chi, CS, “Etching Characteristics of High-Purity Aluminum in Hydrochloric Acid Solutions.” Mater. Sci. Eng., 449–451 (348) 351 (2007)

    Google Scholar 

  28. Singh, DDN, Choudhary, RS, Agarwal, CV, “Corrosion Characteristics of Some Aluminium Alloys in Nitric Acid.” J. Electrochem. Soc., 129 1869–1874 (1982)

    Article  CAS  Google Scholar 

  29. Forooshani, HM, Aliofkhazraei, M, Rouhaghdam, AS, “Superhydrophobic Aluminum Surfaces by Mechanical/Chemical Combined Method and its Corrosion Behavior.” J. Taiwan Inst. Chem. Eng., 72 220–235 (2017)

    Article  CAS  Google Scholar 

  30. Huang, Y, Sarkar, DK, Chen, XG, “Superhydrophobic Nanostructured ZnO Thin Films on Aluminum Alloy Substrates by Electrophoretic Deposition Process.” Appl. Surf. Sci., 327 327–334 (2015)

    Article  CAS  Google Scholar 

  31. Zucchi, F, Grassi, V, Frignani, A, Trabanelli, G, “Inhibitation of Copper Corrosion by Silane Coatings.” Corros. Sci., 46 2853–2865 (2004)

    Article  CAS  Google Scholar 

  32. Zhu, GY, Cui, XK, Zhange, Y, Dong, MY, Liu, H, Shao, Q, Ding, T, Wu, SD, Guo, ZH, “Poly (vinyl butyral)/Graphene Oxide/Poly (methylhydrosiloxane) Nanocomposite Coating for Improved Aluminum Alloy Anticorrosion.” Polymer, 172 415–422 (2019)

    Article  CAS  Google Scholar 

  33. Zhang, H, Yan, L, Zhu, Y, Ai, F, Li, H, Li, Y, Jiang, Z, “The Effect of Immersion Corrosion Time on Electrochemical Corrosion Behavior and the Corrosion Mechanism of EH47 Ship Steel in Seawater.” Metals, 11 1–15 (2021)

    Article  Google Scholar 

Download references

Acknowledgments

The authors are indebted to Department of Mechanical Engineering for access to the equipment (3D noncontact optical profilometer) for characterization under the FIST project grant SR/FST/ET-II/2018/222 (C). A. K. indebted to the SERB (Grant No. DST (TDT)(SHRI)(328)/2022-2023/891/Chemical) for financial support.

Author information

Authors and Affiliations

  1. Department of Chemical Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad, Jharkhand, 826004, India

    Poonam Chauhan, Kushal Yadav & Aditya Kumar

Authors
  1. Poonam Chauhan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kushal Yadav
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Aditya Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

PC contributed to conceptualization, investigation, methodology, and writing—original draft. KY contributed to reviewing and editing and corrosion resistance analysis. AK contributed to supervision, reviewing, and editing.

Corresponding authors

Correspondence to Poonam Chauhan or Aditya Kumar.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Chauhan, P., Yadav, K. & Kumar, A. Effect on the corrosion resistance property of aluminum substrate by altering the wetting behavior. J Coat Technol Res 20, 1639–1648 (2023). https://doi.org/10.1007/s11998-023-00768-5

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11998-023-00768-5

Keywords

Search

Navigation