Adhesion at zinc/alumina interface is a key issue in the field of steelmaking industry, where selective Al oxidation, followed by surface segregation of alumina islands, efficiently impedes wetting of anticorrosive Zn coating on the high strength steel grades. Relying on ab initio total energy calculations, we have examined adsorption of Zn adatoms on different terminations of α-Al2O3(0001) surface under both vacuum conditions and in the presence of surface hydroxyls. Surface configurations with strongly bound Zn and thermodynamic conditions necessary for their stability have been identified. We have shown the existence of a wide range of nonextreme oxygen-rich conditions under which Zn tends to spill over the alumina substrate as an array of strongly adsorbed adatoms, rather than to form metallic clusters weakly bound to the substrate. This effect has been assigned to surface non-neutrality, such as due to surface polarity, or to an excess of surface hydroxyls. Moreover, compared to its direct neighbors in the periodic table (Cu, Ag), we have shown that surface structures with strongly bound adatoms can be stabilized already in much more oxygen-poor conditions.
The control of adhesion at metal/oxide interfaces is of key importance in modern applications, whenever three-dimensional metal clusters or two-dimensional metal overlayers are to be synthesized on an oxide support. By focusing on the zinc/alumina system, we address here one of the long-standing issues in this context, which is the poor wetting of wide bandgap oxides by noble and post-transition metals. It has recently been recognized to have detrimental industrial consequences for the adhesion of anti-corrosive zinc coatings to new high strength steels grades. We have combined photoemission, thermal desorption and plasmonics with atomistic simulation to describe the energetics of zinc deposits on dry and hydroxylated α-Al 2 O 3 (0001) surfaces. Both experimental and computational results show that an activated reaction of the metal with the OHcovered surface, followed by hydrogen desorption, produces dispersed interfacial moieties involving both oxidized Zn species and undercoordinated oxygen ions, that lead to a significant improvement of adsorption/adhesion characteristics on the hydroxylated surface. In particular, the key role of interfacial undercoordinated anions, remnants of the hydroxylation layer, is highlighted for the first time, pointing to a general mechanism by which surface hydroxylation appears as a promising route towards a systematic improvement of wide band gap oxide wetting by metals. 1
With the advent of new steel grades, galvanic protection by zinc coating faces a new paradigm. Indeed, enrichment in strengthening elements prone to oxidation, such as Al, Mn, and Si, leads to the formation of oxide films that are poorly wet by zinc. We study herein routes for the improvement of adhesion at the model Zn/α-Al2O3 interface by the addition of metals. As a first step, with the help of ab initio results on the adsorption characteristics of transition metal adatoms at α-alumina surfaces, we establish and rationalize clear trends in both the behavior of metal-alumina interaction strength and the relative thermodynamic stability of configurations with weakly and strongly bound metal adatoms. The reasons for the enhanced binding strength of transition metals, such as Cr, maintained regardless of the precise alumina termination and the surface charge state are pointed out. On these grounds, possible improvements of adhesion under realistic conditions are discussed. It is predicted that enrichment in transition metals, such as Cr, may produce strongly adhesive interfaces that lead to cohesive cleavage.
The weak interaction between zinc and alumina is responsible for a poor performance of anti-corrosive galvanic zinc coatings on modern advanced high strength steels. In this context, we report a theoretical study on the eect of realistic multi-component metal buers on the adhesion strength of a model-alumina(0001)jzinc interface. Relying on results of ab initio calculations on relevant individual oxidejoxide, oxidejmetal, and metaljmetal interfaces (separation and interface energies), we determine by Monte Carlo simulations the thermodynamically preferred sequence of components in a multicomponent buer, as a function of buer composition and oxygen conditions. We nd that stainless steel buers considerably enhance the overall strength of the aluminajzinc interface. Most importantly, we show that a partial oxidation of multi-component buers, which is unavoidable under realistic conditions, does not degrade their performance. This advantageous property relies on the separation of metal and oxide components in the buer and on the resulting suppression of weakly interacting oxidejzinc, and moderately strong aluminajmetal interfaces. More generally, owing to the possibility of selective oxidation and component segregation, multi-component buers appear as promising solutions for adhesion improvement at weakly interacting metaljoxide interfaces.
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