New anticorrosion siliconized coatings are formed by pyrolytic decomposition of sprayed pure tetraphenoxy silane (TPOS) on surfaces of carbon steel specimens, in a preheated furnace within a temperature range 500–650°C. The optimum conditions for developing highly corrosion resistant siliconized coatings, are decided by the aids of structural and composition analysis techniques. By the aid of EDXRF, SEM, Ultra Sonic Cleaner (USV), cross-edged SEM micrographs, O.M. and Thin Film On Surface (TFOS) software program, the optimal thickness, structure free voids interface and maximum adhesion properties of the produced siliconized coatings, were determined at 600°C for pyrolytical time 45 min. Evaluation of the coatings' composition yielding a high anticorrosion property is fully detailed by the aid of XRD analysis, electrochemical dissolution in different acidic media and adhesion techniques. The microstructure of the optimum siliconized coatings is regular in shape, size, orientation and boundaries of the formed bulky aggregated particles. Also the striations around the coatings' particles are mostly narrow. The strong adhesion property of the coating/metal surface interface, is assessed on the basis of the `go, no go' principle and is related to the inner diffusion of silica (rooting phenomenon). The variation in the constituents' ratios of the produced coatings at different temperatures is attributed to the rate of interconversion of the microcrystallite SiO 2 to crystalline phases and rate of interaction between the diffused iron, Fe 2+, and the crystalline phases of SiO 2. Electrochemical dissolution performance for uncoated and coated electrodes in the range of 0.1–10 M HCl solutions reveal that no significant corrosion behavior is observed. However, the variation between anodic and cathodic routes, is referred to the formation of strong passive irreversible phases on the electrode's surface. These phases could initiate from metal ions (Fe 2+) either provided by the metal surface (in case of uncoated electrodes) or by the siliconized coatings' enriched iron constituents (in case of coated electrodes).
Read full abstract