Abstract
Abstract This study investigates the development of a chromate-free coating system for the corrosion protection of aluminum alloys based on the concept of system approach interface engineering (SAIE) by chemical and plasma techniques. The aluminum alloys investigated include AA2024-T3 ([2B]), AA7075-T6 ([7B]), Alclad 2024-T3 ([2A]), Alclad 7075-T6 ([7A]), plate stock AA2124-T851 ([2P]), and plate stock AA7050-T7451 ([7P]). Direct current (DC) cathodic plasma processes were used to enhance the bonding and protection of spray paint primers on aluminum alloys. Besides anode magnetron enhancement, the DC cathodic plasma processes were also operated with the anode assembly removed, a more practical approach for industrial applications. With appropriate application, DC cathodic plasma coatings provided not only a corrosion-resistant layer on aluminum alloy surfaces but also excellent adhesion bases for spray paint primers, including both chromated and nonchromated water-borne primers. When tested by sulfur diox...
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