Modified Sol–Gel Based Nanostructured Zirconia Thin Film: Preparation, Characterization, Photocatalyst and Corrosion Behavior

Abstract

In this work, AISI 316L stainless steel was coated by nanostructured zirconia using the sucrose assisted sol–gel dip-coating route. Then, the effect of different calcination temperatures and the thickness of the coating on the corrosion protection of 316L stainless steel was investigated. Here, Zr(acac)4 and sucrose were used as starting materials and gelation agents, respectively. Thermogravimetry and differential thermal analysis, X-ray powder diffraction (XRD), Fourier transform infrared, scanning electron microscopy and energy dispersive X-ray spectroscopy were used to characterize the coatings. XRD revealed that the pure tetragonal phase of zirconia was obtained at the calcination temperature of 300–500 °C. However, the mixture of monoclinic (m) and tetragonal (t) phase found in the zirconia coating calcined at 650 °C. Also, by increasing the calcination temperature from 300 to 650 °C, the mean of the crystallite size of structures was increased from 7 to 27 nm. AFM result show that the average roughness value of the sample calcined at 300 °C is 10.5 nm and the dimensions of the particles on the surface of this sample smaller than 50 nm. The potentiodynamic polarization and electrochemical impedance spectroscopy results revealed that the as-synthesized nanostructured sol–gel zirconia coatings exhibited a barrier property for the protection of the substrate. However, the highest corrosion resistance was obtained by the zirconia coating calcined at 300 °C. This was as a result of the desirable compromise of good adhesion, low defect density, and high barrier behaviour. Furthermore, zirconia nanoparticles were synthesized by calcination of the gel at the different temperature. The photocatalytic activity of samples was tested for degradation of methyl orange solutions. It is found that ZrO2 nanoparticles calcined at 500 °C have higher photocatalytic activity than the other samples under UV light.