Deposition Mechanism, Structure and Corrosion Protection of ZrO2-Based Conversion Coatings on AA6060 Primary and Recycled Aluminum Alloys

Abstract

Chemical conversion coatings (CC) are amongst the most common surface pretreatments for aluminium alloys before further organic coating steps. The presence of a conversion layer can increase the resistance towards underpaint corrosion such as filiform corrosion (FFC). Here we explore the deposition mechanism, structure and protective properties against FFC of a ZrO2-based CC on AA6060 aluminium alloy by means of electrochemical techniques as open circuit potential measurements, potentiodynamic polarization and dynamic electrochemical impedance spectroscopy (dEIS). Surface composition and elemental distribution are characterized by X-ray photoelectron spectroscopy (XPS), Glow Discharge Optical Emission Spectroscopy (GD-OES) and Time-of-Flight Secondary Ion Mass Spectrometry (ToF-SIMS). The variation of important parameters such as charge transfer resistance and capacitance during the conversion layer deposition gives insight into the deposition mechanism. GD-OES and XPS shed light into the structure and composition of the formed CC layer constituted of a mixture of Zr (hydr)oxides based products, redistribution of alloy elements and the nature of deposited additives. Finally, FFC tests reveal a comparable performance between primary and recycled alloys.