Effect of Cu2+ on deposition mechanism and structure of ZrO2-based conversion coatings on AA6060 aluminium alloys and their susceptibility to filiform corrosion

Abstract

Zirconium oxide-based conversion coatings (CCs) were prepared from hexafluorozirconic acid, H2ZrF6, with and without CuII as an additive. The CCs were prepared on primary and recycled AA6060. The deposition mechanism, structure, electrochemical properties and effectiveness in protection against filiform corrosion (FFC) have been explored. In presence of CuII additives, a two step deposition mechanism is observed, evidenced by open circuit potential measurements and in situ dynamic electrochemical impedance spectroscopy. Copper deposits predominantly as copper(II) hydroxyfluoride on the top surface, and metallic Cu0 at the metal/CC interface, as evidenced by x-ray photoelectron spectroscopy and glow-discharge optical emission spectroscopy. The presence of a CuII additive induces a different distribution of the ZrO2-based products. After deposition of a weak organic model coating, aluminium pretreated with the CuII-containing system shows a 10%–30% lower maximum filament length compared to the CuII-free system in FFC tests, despite a ca. one order of magnitude higher cathodic activity of the former.