Zinc Substrate Research Articles

Characterisation of the deposition and protection performance of Zr conversion coatings on steel and zinc substrates using the response surface methodology

The response surface methodology (RSM) was used to explore the experimental space, characterise the influence of deposition and drying conditions on corrosion resistance, and evaluate the interactions between these factors for zirconium conversion coatings on cold-rolled steel and zinc. A combination of non-electrochemical drop tests and electrochemical methods were utilised to evaluate corrosion resistance in a dilute Harrison's solution. The surface analysis confirmed the electrochemical results obtained under the conditions chosen by RSM. The uniform corrosion of both substrates guides the subsequent conversion process, while the best coating performance results from the interaction of pH, conversion time and bath concentration.

Stable and reversible zinc metal anode with fluorinated graphite nanosheets surface coating

A highly stable zinc metal anode modified with a fluorinated graphite nanosheets (FGNSs) coating was designed. The porous structure of the coating layer effectively hinders lateral mass transfer of Zn ions and suppresses dendrite growth. Moreover, the high electronegativity exhibited by fluorine atoms creates an almost superhydrophobic solid−liquid interface, thereby reducing the interaction between solvent water and the zinc substrate. Consequently, this leads to a significant inhibition of hydrogen evolution corrosion and other side reactions. The modified anode demonstrates exceptional cycling stability, as symmetric cells exhibit sustained cycling for over 1400 h at a current density of 5 mA/cm2. Moreover, the full cells with NH4V4O10 cathode exhibit an impressive capacity retention rate of 92.2% after undergoing 1000 cycles.

Fabrication of non-wetting surface on zinc substrate with coalescence-induced droplet jumping behavior for atmospheric corrosion protection

In this study, a superhydrophobic surface was constructed on the zinc substrate through a two-step process. The research first examined the correlations between the microstructure and coalescence-induced droplet jumping behavior (CIDJB). Then a droplet jumping phase map was created by considering energy principles. Finally, the performance and mechanism CIDJB in enhancing anticondensation effectiveness and salt spray experiments against atmospheric corrosion were revealed. This study provides insights into designing superhydrophobic surfaces with CIDJB for atmospheric corrosion protection. Further verification of the impact mechanism of environmental factors and stability and durability of CIDJB in practical applications will be investigated.

Influence of Substrate Location and Temperature Variation on the Growth of ZnO Nanorods Synthesized by Hot Water Treatment.

Hot water treatment (HWT) is a versatile technique for synthesizing metal oxide nanostructures (MONSTRs) by immersing metal substrates in hot water, typically in glass beakers. The proximity of substrates to the heat source during HWT can influence the temperature of the substrate and subsequently impact MONSTR growth. In our study, zinc (Zn) substrates underwent HWT at the base of a glass beaker in contact with a hot plate and at four different vertical distances from the base. While the set temperature of deionized (DI) water was 75.0 °C, the substrate locations exhibited variations, notably with the base reaching 95.0 °C. Scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), and Raman spectroscopy showed stoichiometric and crystalline zinc oxide (ZnO) nanorods. ZnO rods on the base, exposed to higher temperatures, displayed greater growth in length and diameter, and higher crystallinity. Nanorods with increasing vertical distances from the base exhibited a logarithmic decrease in length despite identical temperatures, whereas their diameters remained constant. We attribute these findings to crucial HWT growth mechanisms like surface diffusion and "plugging", influenced by temperature and water flow within the beaker. Our results provide insights for optimizing synthesis parameters to effectively control MONSTR growth through HWT.

Chitosan-Surfactant Composite Nanocoatings on Glass and Zinc Surfaces Prepared from Aqueous Solutions.

Hydrophobic coatings from chitosan-surfactant composites (ca. 400 nm thick by UV-Vis spectroscopy) for possible corrosion protection were developed on glass and zinc substrates. The surfactants (sodium dodecyl sulfate, SDS or sodium dodecylbenzenesulfonate, and SDBS) were added to the chitosan by two methods: mixing the surfactants with the aqueous chitosan solutions before film deposition or impregnating the deposited chitosan films with surfactants from their aqueous solutions. For the mixed coatings, it was found that the lower surface tension of solutions (40-45 mN/m) corresponded to more hydrophobic (80-90°) coatings in every case. The hydrophobicity of the impregnated coatings was especially significant (88° for SDS and 100° for SDBS). Atomic force microscopy studies revealed a slight increase in roughness (max 1.005) for the most hydrophobic coatings. The accumulation of surfactants in the layer was only significant (0.8-1.0 sulfur atomic %) in the impregnated samples according to X-ray photoelectron spectroscopy. Polarization and electron impedance spectroscopy tests confirmed better barrier properties for these samples (40-50% pseudo-porosity instead of 94%). The degree of swelling in a water vapor atmosphere was significantly lower in the case of the impregnated coatings (ca. 25%) than that of the native ones (ca. 75%), measured by spectroscopic ellipsometry. Accordingly, good barrier layer properties require advantageous bulk properties in addition to surface hydrophobicity.

Investigation on the effect of laser surface texturing on the wettability of pure zinc substrate

Zinc finds a prominent metallic alternative for existing metallic bio-implant materials. Wettability significantly alters the corrosion resistance and cell adhesion of bio-metallic materials. The wettability of the metallic materials can be engineered by laser surface texturing (LST). In this work, nanosecond laser surface texturing experiments were conducted on the pure zinc substrate by varying the laser scan speed and texture pitch. Laser scan speeds were varied from 10 to 50 mm/s, and the texture pitch varied from 100 to 300 µm. A nanosecond 28 W Nd:YAG laser system was used with 1064 nm wavelength, repetition rate of 5 kHz, focal length of 234 mm, and pulse width of 2 ms. The white light interferometer (WLI) was utilized to explore the surface roughness of the textured samples, and the scanning electron microscope (SEM) was used to investigate the surface morphology. The results revealed that LST on pure zinc follows the Weinzel model which enhances the hydrophobic nature of its surface. Surface roughness plays a significant role in improving the hydrophobic nature of the LST zinc substrates.

Corrosion Resistance Behavior of Zinc Substrate Treated with Rare Earth Salt Passivation

Corrosion Resistance Behavior of Zinc Substrate Treated with Rare Earth Salt Passivation

Enhancing Zinc Electrode Stability Through Pre-Desolvation and Accelerated Charge Transfer via a Polyimide Interface for Zinc-Ion Batteries.

Aqueous zinc-based energy storage devices possess superior safety, cost-effectiveness, and high energy density; however, dendritic growth and side reactions on the zinc electrode curtail their widespread applications. In this study, these issues are mitigated by introducing a polyimide (PI) nanofabric interfacial layer onto the zinc substrate. Simulations reveal that the PI nanofabric promotes a pre-desolvation process, effectively desolvating hydrated zinc ions from Zn(H2O)6 2+ to Zn(H2O)4 2+ before approaching the zinc surface. The exposed zinc ion in Zn(H2O)4 2+ provides an accelerated charge transfer process and reduces the activation energy for zinc deposition from 40 to 21kJ mol-1. The PI nanofabric also acts as a protective barrier, reducing side reactions at the electrode. As a result, the PI-Zn symmetric cell exhibits remarkable cycling stability over 1200h, maintaining a dendrite-free morphology and minimal byproduct formation. Moreover, the cell exhibits high stability and low voltage hysteresis even under high current densities (20mA cm-2, 10 mAh cm-2) thanks to the 3D porous structure of PI nanofabric. When integrated into full cells, the PI-Zn||AC hybrid zinc-ion capacitor and PI-Zn||MnVOH@SWCNT zinc-ion battery achieve impressive lifespans of 15000 and 600 cycles with outstanding capacitance retention. This approach paves a novel avenue for high-performance zinc metal electrodes.

Correlations between the anti-corrosion properties and the photocatalytic behavior of epoxy coatings incorporating modified graphene oxide deposited on a zinc substrate.

This research aimed to create a substrate-coating system based on zinc and an epoxy resin incorporating modified graphene oxide, which possesses two key characteristics: effective resistance against corrosion and the ability to harness photocatalytic properties. Furthermore, correlations between the anti-corrosion properties and the photocatalytic behaviour of the coatings were made. Thin epoxy (EP) layers embedding 0.1 wt% graphene oxide (GO), reduced graphene oxide (rGO), and modified graphene oxide with (3-aminopropyl)-triethoxysilane (APTES) or poly(amidoamine) (PAMAM) dendrimer were applied on a zinc (Zn) substrate using the dip-coating method. Anti-corrosion properties of coated Zn samples were investigated through electrochemical impedance spectroscopy (EIS) measurements. They showed that the corrosion protection effect is more prominent for EP containing functionalized GO, the highest in the case of GO-PAMAM. The results of the EIS measurements indicated also that the corrosion protection provided by EP-rGO is smaller than that of EP. The photocatalytic properties of the coatings were studied by exposure of the samples to Methylene Blue (MB) solution followed by monitoring the model dye degradation through UV-Vis measurements. To determine the changes in the anti-corrosion properties due to photocatalysis, the coated Zn samples were put through additional EIS measurements. The same coatings applied to a glass substrate lacked photocatalytic properties, indicating that the Zn substrate is accountable for the degradation of MB. Furthermore, the incorporation of GO or functionalized GO into the coating amplifies this effect. From EIS spectra, it was determined that the protective properties loss observed after 3 days is due to coating delamination during exposure to MB solution, the EP-GO-APTES retaining the best adhesion of the coating, 98% remaining on Zn after a cross-hatch test. The corrosion measurements were complemented by examining the morphology and structure of the coatings and the modified GO particles. All things considered, the Zn/EP-GO-APTES system shows the best ability to break down organic pollutants, keeping a good anti-corrosive property and adhesion.

Preparation and Corrosion Resistance of Silicate Phosphate Composite Passivation Film on Zinc Substrate by Simple Chemical Impregnation Method

Preparation and Corrosion Resistance of Silicate Phosphate Composite Passivation Film on Zinc Substrate by Simple Chemical Impregnation Method

Wetting and swelling behaviour of N-acetylated thin chitosan coatings in aqueous media

Chitosan nanocoatings (thickness range of 120–540 nm) were produced on glass, zinc and silicon substrates with dip-coating and spin coating techniques to study their pH-dependent wetting and swelling behaviour. The coatings were N-acetylated with the methanolic solution of acetic anhydride to increase the degree of acetylation from 36 % to 100 % (according to ATR-FTIR studies). The measured contact angles of Britton–Robinson (BR) buffer solutions (pH 6.0, 7.4 and 9.0) were lower on the acetylated surfaces (ca. 50°), than that of their native counterparts (ca. 70°) and does not depend on the pH. Contrary, contact angles on the native coating deteriorated 10°-15° with increasing the pH. In addition, for native coatings, the decrease of the contact angles over time also showed a pH dependence: at pH 9.0 the contact angle decreased by 7° in 10 min, while at pH 6.0 it decreased by 13° and at a much faster rate. The constraint swelling of the coatings in BR puffer solutions was studied in situ by scanning angle reflectometry. The swelling degree of the native coatings increased significantly with decreasing pH (from 250 % to 500 %) due to the increased number of protonated amino groups, while the swelling degree of acetylated coatings was ca. 160 % regardless of the pH. The barrier properties of the coatings were studied by electrochemical tests on zinc substrates. The analysis of polarization curves showed the more permeable character of the acetylated coatings despite the non-polar character of the bulk coating matrix. It can be concluded that in the case of native coatings, 49 % of the absorbed water is in bound form, which does not assist ion transport, while in the case of acetylated coatings, this value is only 33 %.

Enhancing the Performance of Reversible Zn Deposition by Ultrathin Polyelectrolyte Coatings.

Modifying the surfaces of zinc and other metallic substrates is considered an effective strategy to enhance the reversibility of the zinc deposition and stripping processes. While a variety of surface modification strategies have been explored, their ability to be practically implemented is not always trivial due to the associated high costs and complexity of the proposed techniques. In this study, we showcase a straightforward method for preparing ultrathin polyelectrolyte coatings using polydiallyldimethylammonium chloride (PDDA) and polyethylenimine (PEI). The coatings, characterized by their electrostatic charge and hydrophobicity, suppress side reactions and even out the electrodeposition process across the substrate surface. The PDDA-coated anodes demonstrate significantly reduced voltage hysteresis, uniform zinc morphology, improved self-discharge rates, and an impressive Coulombic efficiency exceeding 99% over prolonged cycling. Our findings highlight the potential that such cost-effective and straightforward surface treatments could be widely applied in Zn metal-based batteries.

Influence of pH on the Inhibiting Characteristics of Cresol Red Incorporated in Chitosan Coatings on Zinc

The present work focuses on the investigation of protective coatings produced on zinc from chitosan (Chit) and an anionic dye, namely cresol red. Cresol red (CR) fulfills the basic requirements to be used as a corrosion inhibitor because it possesses a relatively high molecular weight and includes in its structure oxygen and sulfur atoms as well as aromatic rings. Moreover, it is an anionic compound that can interact with positively charged chitosan to produce reinforced coatings for zinc anti-corrosion protection. The influence of cresol red as a possible corrosion inhibitor for zinc substrates was investigated either in solution or incorporated in Chit coatings. Two preparation methods for the coatings were used: (i) Chit coating impregnation by immersion in the CR solution after Chit deposition on Zn, and (ii) chitosan mixing with the CR solution before applying the dip-coating technique. Potentiodynamic polarization curves were used to determine the kinetic parameters of the corrosion process. Long-term measurements were carried out in wet/dry cyclic conditions by using electrochemical impedance spectroscopy. EIS measurements recorded in 0.2 g/L Na2SO4 at pH = 7 show an important increase in the impedance of the coatings occurring from the first until the fifty-fifth day in a row, in dry–wet cycles. This increase is due to the beneficial effect of CR incorporated in Chitosan and could be, at least partially, related to a consolidation of the Chit coating structure in the presence of CR by crosslinking between Chit and CR molecules. The structure of the coatings was studied, and the interactions between chitosan and cresol red were put into evidence by using FT-IR spectroscopy. Adhesion and wettability measurements were also carried out. The adhesion of Chit incorporating CR on Zn was better than that on glass substrates and reached ~99.99%, suggesting a better affinity of the chitosan coating towards the Zn substrate due to the existence of ZnO on the substrate surface. All the results show that CR could be used on zinc as a corrosion inhibitor incorporated in chitosan at basic pHs, but without taking advantage of its pH-indicating properties, which are lost due to the interactions occurring between the positively charged biopolymer and the negatively charged dye molecule. The preparation method of Chit coating impregnation with CR by immersion in the solution after deposition on Zn led to poorer results than the method in which chitosan was previously mixed with CR before applying the dip-coating technique.

Construction of ultrastable and high-rate performance zinc anode with three-dimensional porous structure and Schottky contact

The artificial interface layer on the Zn anode can effectively suppress by-product formation and dendrite growth, playing a crucial role in achieving high-rate and long-life aqueous zinc-ion batteries. However, the current galvanizing mode, where plating occurs separately below or inside the interface layer after its introduction, poses risks of detachment or swelling during cycling, limiting practical applications. In this study, we fabricate a three-dimensional porous NiO interface layer with enhanced anode dynamics that forms a Schottky contact with the zinc substrate. Through the synergistic effect of this excellent structure and Schottky barrier, zinc is rapidly and uniformly plated both inside and below the interface layer simultaneously. Symmetrical cells based on NiO@Zn exhibit exceptional stability over 10,000 cycles at an ultrahigh current density of 20 mA cm−2. Furthermore, NiO@Zn||MnO2 full cells deliver a capacity of 228 mAh g−1 and retain 94% of their initial capacities for 500 cycles at a density of 1 A g−1. This work not only presents highly reversible zinc anodes but also proposes an innovative galvanizing model.

Enhancing corrosion inhibition of zinc with biomimetic slippery liquid-infused porous surfaces (SLIPS): An on-site fabrication strategy

Biomimetic Slippery Liquid-Infused Porous Surfaces (SLIPS) represent a promising solution for protecting metallic materials from the threats of corrosion. However, the practical use of SLIPS coating faces substantial obstacles, primarily stemming from the complexities of surface microstructures and the presence of oil layer. These factors present significant challenges in terms of fabrication, transportation and overall effectiveness of the coating. In response to these challenges, the concept of on-site fabrication is proposed as a promising alternative in this study. Instead of relying on the prefabrication paradigm, this approach involves generating SLIPS right at the location where they will be used. For executing the on-site fabrication, the routes and processes have to be facile and easy to realize. To explore this on-site fabrication strategy, our study involves the reconstruction of zinc through a displacement reaction with tin salt solution, resulting in the creation of a dendritic structure. Subsequently, a straightforward modification using a hydrophobic compound dodecanethiol confers superhydrophobicity to the surface. Introducing a lubricant into superhydrophobic matrix achieves SLIPS coating, which is proved to highly enhance corrosion resistance to the underlying zinc substrate. The corrosion current density of zinc decreases significantly, dropping from the initial 1.92 × 10−4 A/cm2 on bare zinc to a mere 5.65 × 10−7 A/cm2 with SLIPS coated on metal surface. Furthermore, the use of SLIPS provides the metal substrate with increased resistance to icing. By resorting to the facile routes without the requirement of the rigid conditions, this on-site fabrication strategy poses significant promise for practical application of the versatile SLIPS coating.

Development of superhydrophobic layered double hydroxide directly on zinc substrate: structural and corrosion resistance properties

Development of superhydrophobic layered double hydroxide directly on zinc substrate: structural and corrosion resistance properties

Epoxy Coatings Doped with (3-Aminopropyl)triethoxysilane-Modified Silica Nanoparticles for Anti-Corrosion Protection of Zinc

Epoxy (EP) coatings containing silica (SiO2) and (3-Aminopropyl)triethoxysilane-modified silica (SiO2-APTES) nanoparticles were prepared via the dip-coating technique on a zinc substrate. A detailed study was performed regarding their incorporation into the matrix, followed by the investigation of the newly obtained organic–inorganic hybrid coatings’ anti-corrosive properties. The two methods of embedding the nanoparticles were (I) modification of the silica nanoparticles with APTES followed by their introduction into the epoxy resin, and (II) functionalization of the silica nanoparticles in the epoxy gel before the addition of the hardener. It was observed that through the second method, the coating was homogeneous, with no sign of agglomerates. The nanoparticles were subjected to morpho-structural and physical–chemical analysis using Fourier-Transform Infrared Spectroscopy and Transmission Electron Microscopy, while the coatings were examined through Scanning Electron Microscopy and Energy-Dispersive X-Ray Spectroscopy, contact angle measurements and adhesion tests. The anti-corrosive performance of epoxy-coated zinc was analyzed using electrochemical impedance spectroscopy and polarization curves to investigate the impact of silanized SiO2 nanoparticle incorporation. Based on long-term corrosion testing, the epoxy-SiO2-APTES composite coatings showed a higher corrosion resistance than the undoped epoxy layer.

Hot deformation and fatigue behaviour of a zinc base doped biocompatible material: characterization of plasma spray coating on surface

Composite materials are natural or man-made substances put into the body to turn a living cell into a working organ. Bone tissue and biocompatibility are emerging as an alternative approach to regenerating bone due to some distinct advantages over autografting. This research aimed to fabricate a novel porous scaffold that can be utilized as a bone substitute. Zn-nHApx-Srx (x = 0, 3, 6, 9) was selected by different weight ratios and synthesized using the powder metallurgy method. The utilization of nanohydroxyapatite (Ca10(PO4)6(OH)2) is due to its excellent biocompatibility with the human body. Polylactic-co-glycolic acid (PLGA) is incorporated to get enhanced biological performance. Plasma spray coating was performed on a zinc substrate using pure and doped biocomposites calcined at 800 °C. The biocomposites tensile strength increased between 0.4 and 19.8 MPa by increasing Zn and Sr weight ratios. In addition, 3% Sr/2.5% Zn with 2% of nHAp-PLGA composite showed improved hardness, which is beneficial for resembling bone tissue and die-casting fittings in automobile manufacturing applications. Mechanical properties, FT-IR, hot deformation behaviour, and SEM techniques help us understand the behaviour of Zn-Sr-nHAp in a vial containing PLGA. The highest ultimate tensile strength of 182 MPa and improved flow softening behaviour are achieved in a coated Zn/6% (nHAp-Sr) mixture suitable for biodegradable implant applications.

A High-Performance Antibacterial Nanostructured ZnO Microfluidic Device for Controlled Bacterial Lysis and DNA Release.

In this work, the antibacterial properties of nanostructured zinc oxide (ZnO) surfaces are explored by incorporating them as walls in a simple-to-fabricate microchannel device. Bacterial cell lysis is demonstrated and quantified in such a device, which functions due to the action of its nanostructured ZnO surfaces in contact with the working fluid. To shed light on the mechanism responsible for lysis, E. coli bacteria were incubated in zinc and nanostructured ZnO substrates, as well as the here-investigated ZnO-based microfluidic devices. The unprecedented killing efficiency of E. coli in nanostructured ZnO microchannels, effective after a 15 min incubation, paves the way for the implementation of such microfluidic chips in the disinfection of bacteria-containing solutions. In addition, the DNA release was confirmed by off-chip PCR and UV absorption measurements. The results indicate that the present nanostructured ZnO-based microfluidic chip can, under light, achieve partial inactivation of the released bacterial DNA via reactive oxygen species-mediated oxidative damage. The present device concept can find broader applications in cases where the presence of DNA in a sample is not desirable. Furthermore, the present microchannel device enables, in the dark, efficient release of bacterial DNA for downstream genomic DNA analysis. The demonstrated potential of this antibacterial device for tailored dual functionality in light/dark conditions is the main novel contribution of the present work.

Unveiling the relationship between MOF porosity, particle size, and polyethersulfone membranes properties for efficient decontamination of dye and organic matter

This work investigates the impact of reaction time on the textural properties and nanoparticles growth of metal organic framework (MOF) obtained from zinc substrate and their subsequent impact on the performance of polyether-sulfone (PES) ultrafiltration membranes. The MOF nanoparticles were synthesized at various reaction times between 2 and 8 h and then immersed in ascorbic acid to improve their hydrophilicity. A decline in the particle size with significant rise in the textural properties was noticed by decreasing the reaction time. Moreover, shifting of oxygen functional groups (–OH and C–O) was obtained after acid treatment. Next, 1.5 wt% of the acid treated MOFs were blended in the PES polymer for the formation of the hybrid membranes. The porosity, contact angle, water flux, surface morphology, and roughness were characterized for the resulting membranes. Moreover, the hybrid membranes were tested against the rejection of Eriochrome Black-T (EBT) and Humic acid (HA) pollutants. The characterization outcomes illustrated an incremental rise in hydrophilicity, porosity, and surface roughness of the hybrid membranes by decreasing the reaction time of the MOF nanoparticles. The water flux steadily improved by decreasing the reaction time of the MOFs. The maximum flux was 427.7 L m−2h−1 which was 2.2 times higher than the flux of the bare membrane. The elimination of EBT and HA, flux recover ratio and fouling resistance of both pollutants were improved by decreasing the particle size of MOFs. Overall, this study discloses that tuning the reaction time of MOF significantly influence the effectiveness of PES membranes in water treatment systems.