Corrosion Durability Research Articles

Corrosion Resistance of Li-Al LDHs Film Modified by Methionine for 6063 Al Alloy in 3.5 wt.% NaCl Solution

Methionine (Met) was introduced to modify the Li-Al layered double hydroxides (LDHs) film prepared on 6063 aluminum alloy by in situ method for the first time. Fourier transform infrared spectroscopy, X-ray photoelectron spectroscopy, Scanning electron microscopy, and X-ray diffraction confirmed the successful insertion of Met into LDHs film and revealed that the introduction of Met could make the LDHs film much denser. Electrochemical tests illustrated that the corrosion rate of the Met modified LDHs film was reduced by more than an order of magnitude compared with the bare Al alloy. Moreover, the corrosion rate of the modified LDHs film after immersion in 3.5 wt.% NaCl solution for 21 days was almost the same as that without immersion, which indicates that the modified film has good corrosion durability. The corrosion resistance of the scratched modified film could recover to the level without a scratch on the 14th day based on the scratch test results, meaning the modified film has a good self-healing property. Finally, the anti-corrosion mechanism of the Met was proved by molecular dynamic simulations and found that the enhanced corrosion resistance may be attributed to the addition of Met that slowed the diffusion of the corrosive medium Cl− and water molecules.

Effect of Surface Modification on the Characteristics of Sisal Fiber Reinforced Concrete Treated with Na2CO3

Concrete with fiber as a reinforcing material is one of the important fields of research that is gaining traction in this upcoming green technology revolution. By adding fibers to concrete, the tensile strength properties are vastly improved without compromising the strength characteristics, and cost fluctuation is minimal. This research is being carried out to improve the qualities of concrete that have been infused with chemically treated sisal fiber in varied ratios. The paper investigates and describes the effects of sisal fiber when it is chemically treated and infused with concrete, comparing it to ordinary concrete in strength tests. Water absorption, workability, and other material characteristics of Sisal fiber reinforced concrete with 0.5 per cent, 1 per cent, 1.5 per cent, and 2 per cent fiber replacing cement by volume fraction and a sisal fiber aspect ratio of 1:100 are compared to the traditional M30 concrete grade. After being treated with an alkaline solution, 0.5 per cent and 1 per cent sisal fiber reinforced concrete increased tensile and compressive strength, as well as the formation of calcium carbonate deposits on the fiber interfaces; this also contributes to the concrete’s corrosion resistance and durability.

Long-term experimental evaluation and molecular dynamics simulation of polypropylene/graphene oxide nanocomposite coating in 3.5 wt% NaCl solution

Most organic coatings lose their resistance over time. In this work, the super-hydrophobic polypropylene (PP) coating was developed by dip-coating method to avoid destructive agents penetration into the mild steel substrate and provide long-term corrosion protection. Graphene oxide (GO) was put in the PP matrix to improve corrosion durability by reducing wettability. PP grafted with maleic anhydride (PP-g-MAH) was also utilized to elevate the bond strength and adhesion of the coating to the undercoat. The PP coating formed in the solution contained 50 wt% PP-g-MAH and 0.1 wt% GO (named as PP/PP-g-MAH/GO-0.1) illustrated the best durability performance after 30 days of immersion by corrosion resistance of 5200 Ω·cm2, which is 25 times greater than the pure PP sample. Moreover, the positive effect of the GO on the efficiency of the PP/PP-g-MAH/GO-0.1 sample was proved by maintaining super-hydrophobicity after 1 week of immersion (water contact angle (WCA) of 152°). Furthermore, MD simulations were performed to verify the improvement of WCA owing to the presence of GO. The results reveal that this additive acted as an effective barrier against penetrating agents by growing WCA (50°).

Development of High Performance Superhydrophobic Coating Using M-Tio2@Ep Composites with Excellent Corrosion Resistance, Durability and Self-Cleaning

Development of High Performance Superhydrophobic Coating Using M-Tio2@Ep Composites with Excellent Corrosion Resistance, Durability and Self-Cleaning

A Comparative Analysis of Ternary Element Addition on Corrosion Behavior of Aluminide Coatings in Harsh Environmental Conditions

Increasing hot corrosion durability of aluminide coatings is important to extend the lifetime of turbine blades. The addition of hafnium, yttrium, zirconium, chromium, platinum, and cobalt improves the performance of aluminide coating by increasing oxide adherence and selective oxide formation rate. In this research, the effect of adding ternary elements (Y, Cr, Y/Cr, Zr, and Hf) on type-1 hot corrosion behavior of aluminide coatings was investigated by an accelerated isothermal corrosion test at 900°C for up to 400 h. To simulate harsh environmental conditions, Na2SO4- and V2O5-containing solutions were applied to the substrate surface. Subsequently, for 1 h, 50 h, 100 h, 200 h, and 400 h exposure times, the oxide layer thicknesses, spallation time, coating layer depletion time, and elemental analysis of each set were analyzed and their performances compared.

A Robust Superhydrophobic/Conductive Composite Coating with Excellent Anticorrosive Performance

AbstractCorrosion has caused huge economic losses each year in the world. Here, a robust superhydrophobic polysiloxane and metal oxide conductive polyaniline composite coating (POS‐RA‐OPAN) was prepared based on the innovation problem theory and the method (TRIZ), the superhydrophobic polysiloxane layer is mainly used to reduce chemical corrosion and the metal oxide conductive polyaniline composite layer is mainly used to reduce electrochemical corrosion. Contact angle (CA) and sliding angle (SA) of POS‐RA‐OPAN reach 157.4°±2.1 and 5.3°±1.5, respectively. Its protection efficiency is 99.99 %, the CA is only reduced to 148.1° from the initial 157.4° after the 196 times peeling tests. The open‐circuit potential (Eocp) remains at a high potential of 178 mV after the immersion of 792 h. POS‐RA‐OPAN has excellent superhydrophobicity, corrosion resistance, mechanical properties and corrosion durability.

SMOOTH AND REDUCED OIL AND GAS PIPES WITH INCREASED CORROSION RESISTANCE

Formulation of the problem. Corrosion of pipes used in the oil and gas industry leads to significant economic losses, therefore, increasing their corrosion resistance and durability is an urgent task. Purpose: generalization of results of developments of technologies of manufacturing and research of qualitative characteristics of oil and gas pipelines (smooth) and pump-compressor (threaded) pipes of the increased and high corrosion resistance and giving recommendations on their application in oil and gas industry in environments of various corrosion aggressiveness. Methodology. The microstructure of tubular steels and protective coatings was studied by light metallography and electron microscopy. Complex corrosion studies included laboratory tests of samples in model chloride and hydrogen sulfide-containing media, the resistance to sulfide corrosion cracking under stress (SCCS) and hydrogen cracking (НС) according to the methods of NACE TM 0177 and NACE TM 0284 as well as operational tests at the oil fields of Ukraine. Mechanical properties for stretching and impact bending of samples by standard methods. Results. The results of the development of production technologies and the study of the qualitative characteristics of oil and gas pipelines and tubing with increased and high corrosion resistance in aggressive oil and gas production environments are summarized. The influence of the chemical composition of steels and protective coatings, as well as pipe manufacturing technologies on their microstructure, corrosion resistance in various media, and mechanical properties is shown. Scientific novelty. For the first time, the presence of special low-energy boundaries in the ferrite of low-alloy ferrite-pearlite and high-alloy ferritic-austenitic steels was established, their number and energy level were estimated. The high operational reliability of threaded pipes with a protective coating is substantiated. Practical value. The results of the work and recommendations for the rational use of oil and gas pipes with increased corrosion resistance can be used to increase the economic efficiency of production in the oil and gas industry.

Estimation of the Filled Two-Component Cold Curing Polymer System Performance as a Coating for Protecting Concrete Surfaces from the Aggressive Environment Exposure

A filled two-component polymer cold curingsystem (FTCPS) is discussed in the article. To assess its corrosion resistance and durability, the indexes of reagent resistance were determined in accordance with the sorption method. What is optimal, since this value depends on the parameters of mass transfer, the intensity of the reaction, the size of the product, the duration of exposure to aggressive media and other factors. As aggressive media were taken: water, 5% hydrochloric acid solution, 25% aqueous ammonia solution, 10% sodium hydroxide solution, saturated sodium chloride solution. The exposure time was 360 days. Reagent resistance evaluation of the developed FTCPScompositionswas carried out on the basis of guidelines for determining the anticorrosive properties of protective coatings of concrete and laboratory test methods. Changes in the mass of the samples and their reagent resistance as a result of exposure to chemical reagents simulating an aggressive environment during operation were evaluated. The change in the index of reagent resistance in laboratory conditions did not go beyond the value of 0.80, which makes it possible to ensure reliable protection and operation of polymer-coated products under conditions of exposure to these aggressive environments.

Research on the wettability of localized pulse electrolytic machining mold steel (GCr12)

As one of the most widely used metal materials, steel takes on an important role in deep sea and space exploration fields. However, the annual economic loss caused by steel corrosion is immeasurable. To resolve the problem, the localized pulse electrochemical machining (PECM), an efficient, fast and environment-friendly method, was introduced to fabricate microstructures on the surface of mold steel (GCr12). Results show that a super-hydrophobic surface has been obtained and its corrosion resistance has been significantly enhanced without the need to modify the surface by low surface energy solution. Thanks to the optimal working parameters (7.9 V and 2 ms) identified from the processing, the water contact angle of 161.8° was obtained. After fabrication by PECM, the surface microstructure, chemical element, and wettability were characterized and analyzed by scanning electron microscope (SEM), laser scanning confocal microscope (LSCM), EDS energy spectrometer, and optical contact angle measuring instrument, respectively. According to the experimental results, the surface honeycomb structure (micro/nano binary structure) is proven to be the main factor affecting wettability. Next, durability tests and corrosion resistance tests were carried out and the contact angle decreased by 4.4% and 6.7% respectively compared with the original contact angle, indicating that the surface after PECM has strong durability and good corrosion resistance, which can effectively solve the corrosion problem of steel. Therefore, using localized PECM technology to prepare microstructure on the surface of mold steel has a good application prospect in industry.

Fluorine-Decorated Graphene Nanoribbons for an Anticorrosive Polymer Electrolyte Membrane Fuel Cell.

Pt-supported carbon material-based electrocatalysts are formidably suffering from carbon corrosion when H2O and O2 molecules are present at high voltages in polymer electrolyte membrane fuel cells (PEMFCs). In this study, we discovered that the edge site of a fluorine-doped graphene nanoribbon (F-GNR) was slightly adsorbed with H2O and was thermodynamically unfavorable with O atoms after defining the thermodynamically stable structure of the F-GNR from DFT calculations. Based on computational predictions, the physicochemical and electrochemical properties of F-GNRs with/without Pt nanoparticles derived from a modified Hummer's method and the polyol process were investigated as support materials for electrocatalysts and additives in the cathode of a PEMFC, respectively. The Pt/F-GNR showed the lowest degradation rate in carbon corrosion and was effective in the cathode as additives, resulting from the enhanced carbon corrosion durability owing to the improved structural stability and water management. Notably, the F-GNR with highly stable carbon corrosion contributed to achieving a more durable PEMFC for long-term operation.

Chelation Assembly of Cellulose Nanohydrogel onto Flower-Like Structured Foam with Underwater Superoleophobicity for Highly Efficient Oil–Water Separation

Currently, with the increasingly serious pollution problem of oily wastewater, it is urgent to develop advanced materials and methods. In this work, a Fe(III)-CMC@Ni(OH)2@Ni composite foam with superhydrophilic and underwater superoleophobicity was fabricated by an in situ growth of flower-like Ni(OH)2 nanoparticles and chelated assembly of Fe(III)-CMC nanohydrogel via a layer-by-layer self assembly using [Formula: see text] ion and carboxymethyl cellulose (CMC). The composite foam could separate various oil/water mixtures and exhibited excellent efficiency over 99%. This foam possessed ultrahigh water flux (220000[Formula: see text]L [Formula: see text] [Formula: see text] and better resistant to penetration pressure (1.3[Formula: see text]kPa). After 30 cycles, the oil–water separation performance reduced only 0.5%, but the foam structure was still stable that guarantees a better lifetime. Besides, this composite foam showed anti-fouling, unique durability and excellent corrosion resistance performance. Taking into account all good properties, Fe(III)-CMC@Ni(OH)2@Ni composite foam was expected to be a potential candidate for responding to all kinds of complex oily wastewater conditions.

Designing and Exploring a Brand-new Strong Superhydrophobic-Conductive Polyaniline-Polysiloxane Composite Anti-corrosion Coating

Abstract The superhydrophobic-conductive anti-corrosion mode has attracted much more attention due to the huge economic losses of stainless steel corrosion. Here, a brand-new strong superhydrophobic-conductive polyaniline-polysiloxane (PANIC-RA-POS) anti-corrosion coating was prepared. The internal conductive and dense interpenetrating network polyaniline layer can effectively reduce electrochemical corrosion, the external superhydrophobic polysiloxane layer can effectively decrease chemical corrosion, the adhesive layer obviously improves the binding force of polyaniline and polysiloxane layer, and furthermore, it has excellent protection efficiency, corrosion durability and binding force.

Cathode durability enhancement under start-up/shut-down process using IrRuOx/C catalyst in polymer electrolyte membrane fuel cell

The disruptive degradation of the electrode in the membrane electrode assembly (MEA) under the transient situation during the fuel cell electric vehicle operations such as fuel starvation, start-up and shut-down (SU/SD), etc. is to be addressed. To mitigate the carbon corrosion in the electrode, the catalyst for oxygen evolution reaction (OER) has been investigated recently. It evolves oxygen from water, thereby mitigating carbon corrosion at voltages over 1.5 V, which is typically induced during SU/SD cycles. In this study, carbon-supported IrRuOx catalysts towards OER are synthesized using a sub-substrate method, and their electrochemical and physicochemical properties are analyzed using several methods. Ir1Ru1Ox (Ir:Ru = 1:1 at. ratio in the oxide form) is observed to be the best catalyst in terms of activity and durability. The application of a 2.5 wt% OER catalyst to the cathode improves the carbon corrosion durability of the MEA by approximately 88 %. After 4000 SU/SD cycles, the electrochemical surface areas of the Pt in the OER-added MEA and reference MEA are reduced by 15 % and 57 %, respectively. When the OER catalyst is applied to the reference cathode electrode, it enhances the durability of the MEA without compromising the performance significantly.

ASSESSMENT OF THE INFLUENCE OF MANGANESE CONTENT ON THE CORROSION OF THERMALLY HARDENED METAL

In this work, we studied the corrosion behavior of hot-rolled and heat-hardened rolled products made of low-carbon steel with different manganese content in it in order to select the optimal conditions for its heat treatment to obtain a satisfactory combination of strength and corrosion resistance during the development of general corrosion processes with hydrogen polarization. A promising way to save metal in construction, mechanical engineering and transport, as well as to reduce the consumption of alloying elements and deoxidizers as a result of replacing, in some cases, low-alloy structural steels with simpler and less costly low-carbon ones, is the use of hardening heat treatment, especially using the heat of rolling heating. However, the widespread use of thermally hardened rolled products of thinner thickness in order to save metal in structures and structures exposed to the surrounding, as a rule, corrosive environments of various nature and intensity, comes across a completely insufficient study of the corrosion behavior of such a material as an energetically more unstable system than a conventional hot rolled steel products. It is the hot-rolled state that is attributed to the scientific data on the corrosion behavior of carbon and low-alloy structural steels, which are far from systematic and not unanimous in their assessments, and the data on the corrosion of heat-hardened rolled steel, as a metastable system with increased free energy, are limited and contradictory. Therefore, the study of the laws governing the behavior of thermally hardened rolled metal as a metastable metal system is of great practical importance for the choice of processing technology and materials that would provide a satisfactory combination of strength and ductility of thermally hardened rolled metal. The studies were carried out on samples of low-carbon steel of laboratory heats, having in their chemical composition approximately the same content of C, Si, S, P, Cu and different content of Mn (0,66, 1,00 and 1,68 % by mass) in hot-rolled and thermally hardened conditions (quenching from 880-900 oC, and then tempering was carried out in the temperature range 200-700 oC every 25-50 oC for 1 hour, followed by cooling in calm air). Corrosion tests were carried out on polished and degreased samples constantly immersed in 1 N H2SO4 solution at room temperature for 72 h. It was found that alloying low-carbon steel with manganese (up to 2 %) leads to an increase in the corrosivity of the metal in a thermally hardened state, shifts the peak of corrosivity during tempering towards a lower temperature (from 475 to 375 oC) and increases corrosion losses in the region of the peak in 1, 6 times. It is shown that after quenching and high tempering (at temperatures > 600 oC), on the contrary, in steel with an increased manganese content, corrosion losses, for example, in an acidic environment, are significantly reduced due to the fact that manganese accelerates the processes of coagulation of carbide particles. It is recommended to carry out heat hardening treatment of structural steel with an increased (1,5 %) manganese content while satisfying the technical requirements for a combination of strength and satisfactory corrosion durability; it is advisable to prescribe a tempering (self-tempering) of at least 600 oC for heat hardening. In this case, with a significant gain in strength (increase by 20-25 %), it is possible to achieve a higher corrosion resistance of the metal in comparison with the hot-rolled (unhardened) state.

Salt-responsive ZnO microcapsules loaded with nitrogen-doped carbon dots for enhancement of corrosion durability

Capsules containing corrosion inhibitors have drawn considerable attention in the field of self-healing corrosion protection because of their appropriate size and high efficiency. ZnO has become a type of promising encapsulants due to its high structural tunability and unique surface chemical property. Meanwhile, carbon dots (CDs) have huge application potential to replace the existing toxic corrosion inhibitors. Herein, a corrosion-resistant microcapsule with nitrogen-doped carbon dots (NCDs) as the core material and ZnO as the wall material (NCD@ZnO MCs) was developed to exert perfectly the advantages of the two materials. The NCDs were first synthesized by solvothermal method, and the NCD@ZnO MCs were then fabricated just by stirring at room temperature. The morphology, microstructure and composition of NCDs and NCD@ZnO MCs were characterized, respectively. The superiority of NCD@ZnO MCs in improving the anti-corrosion resistance of waterborne coatings was also discussed. The results showed that the obtained NCDs had a size distribution of 2–5 nm and the N-doping content was 6.56%. The size distribution and shell thickness of the prepared NCD@ZnO MCs were 100–200 nm and 30–90 nm, respectively. The encapsulation efficiency of NCDs was 34.69 ± 3.04%. The release behavior of NCD@ZnO MCs exhibited a dependence on salt concentration. Electrochemical impedance spectroscopy (EIS) measurements showed that NCD@ZnO MCs as fillers significantly improved the durability of the coating in terms of anti-corrosion resistance in all solutions with different salt concentrations. This smart filler is a promising candidate for application in anti-corrosive coatings, due to its low toxicity, facile synthetic route, near nanoscale size and sensitive environmental responsiveness.

Failure Analysis of Air Vent Connected with Heat Supply Pipeline Under Manhole, 맨홀에 설치된 지역난방 열공급관 에어벤트의 전단부 파손 원인 규명

The air vent connected to a heat supply pipeline in the district heating system has been used to eliminate the existing air in the pipe, which has a detrimental effect on corrosion durability and heat efficiency. Recently, the air vent installed under a manhole for 22 years was corroded and several pinholes were detected in the front-end of the air vent. To identify the cause of the failure, thickness reduction, corrosion products, and water quality were examined. The corrosion damage was significant at the outside of the front-end of the air vent where the insulator was covered. While a thin oxide layer was formed in the interior of the tube, the coarse and porous corrosion products consisting of magnetite and hematite were found externally. Water flowing into the thermal insulator was absorbed by the insulator following hydrolysis. The hydrolyzed insulator ejected the corrosion factors such as Cl-, SO4 2-, and NH4 +. The findings suggest that the corrosion under insulation due to rain water is the main cause of the underlying failure in the air vent.

Rottenstone as a basis for obtaining geopolymer material

The possibility of obtaining perspective geopolymer materials for use in the building industry was shown. Geopolymer materials are used with such advantages as high strength, density, water resistance, heat and heat resistance, environmental friendliness, durability, and high corrosion resistance. The raw material is rottenstone, a rock with a high silica content, which is widespread in Ukraine. Rottenstone is characterized by a ratio of SiО2:Al2O3 equal to 16… 20, which provides a high strength of the final material. It was indicated that physico-chemical processes that take place during polymerization are similar to those that take place in thin pellicles of the released SiO2 gel, cements the particles, and thus promotes hardening. As a result of the treatment of raw materials with alkali solution at temperatures of 80-120 °С, a monolithic solid material of olive color with a density of 1200-1700 kg/m3, humidity of 30-45% was formed. Precipitations were observed on the surface of the material due to the presence of non-chemically bound sodium and potassium cations in the pores of the geopolymer. When dried, they diffuse to the surface of the geopolymer and are subjected to atmospheric carbonization. It was indicated that in order to obtain a high-strength geopolymer material, it is necessary to carry out final heat treatment at temperatures close to 100 °С. The behavior of geopolymer samples aged over time at room temperature during their heating was investigated. The samples of the material are melted due to the presence of Na2O×SiО2×8Н2O and Na2O×SiО2×5Н2O crystal hydrates, which melt at relatively low temperatures at 48°С and 72°С, respectively. The formation of building geopolymer materials should take into account this melting by placing it in molds was concluded. Indicators of moisture loss at a temperature of about 100°С depending on the heat treatment time were obtained.

Assessment of Internal Structure of Spun Concrete Using Image Analysis and Physicochemical Methods.

Taking into account the possibilities offered by two imaging methods, X-ray microcomputed tomography (µCT) and two-dimensional optical scanning, this article discusses the possibility of using these methods to assess the internal structure of spun concrete, particularly its composition after hardening. To demonstrate the performance of the approach based on imaging, laboratory techniques based on physical and chemical methods were used as verification. Comparison of obtained results of applied research methods was carried out on samples of spun concrete, characterized by a layered structure of the annular cross-section. Samples were taken from the power pole E10.5/6c (Strunobet-Migacz, Lewin Brzeski, Poland) made by one of the Polish manufacturers of prestressed concrete E-poles precast in steel molds. The validation shows that optical scanning followed by appropriate image analysis is an effective method for evaluation of the spun concrete internal structure. In addition, such analysis can significantly complement the results of laboratory methods used so far. In a fairly simple way, through the porosity image, it can reveal improperly selected parameters of concrete spinning such as speed and time, and, through the distribution of cement content in the cross-section of the element, it can indicate compliance with the requirement for corrosion durability of spun concrete. The research methodology presented in the paper can be used to improve the production process of poles made of spun concrete; it can be an effective tool for verifying concrete structure.

Characterization of water-repellent and corrosion-resistant superhydrophobic surfaces on galvanized steel

Corrosion-resistant superhydrophobic surfaces were successfully fabricated on galvanized steel through a wet oxidation treatment and stearic acid modification. In this work, the formation mechanism of superhydrophobic surfaces and structures were characterized with contact angle meter, scanning electron microscope (SEM), X-ray diffractometer (XRD), and Fourier transform infrared spectroscopy (FTIR). The surface properties of superhydrophobic and non-superhydrophobic surfaces were assessed by calculating surface free energy (γ) and work of adhesion (Wst). Moreover, the corrosion behavior and durability of superhydrophobic surfaces were examined in 3.5 wt% NaCl solution for up to 14 days. Superhydrophobic galvanized surfaces with WCAs of 168° (γ = 0.01 mN/m and 1.57 mN/m) and 162° (γ = 0.04 mN/m and Wst = 3.52 mN/m) were successfully obtained by modifying HCl etched surfaces with ethanolic stearic acid, with or without wet oxidation. According to the results, a zinc stearate layer on the surfaces effectively enhanced their corrosion resistance by numerous air pockets on the surfaces with hierarchical micro-/nanostructures that inhibited penetration by the NaCl solution. Moreover, superhydrophobic as-synthesized ZnO surface by wet oxidation had better corrosion durability than a superhydrophobic etched surface because of the strong physical and chemical bonding of stearic acid onto the as-synthesized ZnO nanorods.

Analysis of effects of process factors on corrosion resistance of adhesive bonded joints for aluminum alloys

Abstract In the adhesive bonding process, the hydrolytic stability or corrosion resistance is of significant importance in achieving acceptable joint durability. The aim of this study is to identify the process factors affecting corrosion durability of adhesive bonded joints for aluminum alloys. For this purpose, experiments were carried out to investigate the influence of varying the surface treatment-primer-adhesive combination. The tests used for the evaluation of corrosion resistance included neutral salt spray and floating roller peel testing. In addition, the residual peel strengths after 300 days of exposure to salt spray were statistically analyzed using analysis of variance (ANOVA) and Tukey test (α=0.05) in order to understand the interaction effects between the process factors. The surface morphology, chemical composition and oxide thickness played a major role in the control of adhesion performance and joint durability. In particular, a hybrid sol-gel coating consisting of TPOZ (zirconium n-propaxine) and γ-GPS (γ-glycidoxypropyltrimethoxysilane) produced a microscopically rough surface with an increased surface energy compared with the standard phosphoric oxide. Furthermore, a non-chromate primer exhibited adequate corrosion protection efficiency when used with a sol-gel coating. The incorporation of zirconium oxide (ZrO2) in the sol-gel coating increased surface densification through pore-filling and planarization, finally resulting in high corrosion durability.