In this work, the influence of water immersion post-treatment, with consideration of temperature and pH values, on trivalent chromium conversion coating morphologies, compositions and corrosion protection has been investigated, using high-resolution transmission electron microscopy, energy-dispersive X-ray spectroscopy and electrochemical impedance spectroscopy. Compared to the coating formed without the water immersion post-treatment, the post-treatment in the deionized water bath at 40 • C evidently reduced the concentrations of fluorine-containing constituents and increased the extent of oxides/hydroxides across the coating. Consequently, the enhanced corrosion protection property was investigated in the post-treated coatings during full immersion in naturally-aerated NaCl solution with mass fraction of 3.5%. In terms of water pH effects, the coatings displayed comparable thicknesses after post-treatment in the as-prepared deionized water bath (pH 5) and neutral water bath (pH 7); However, a considerable shrinkage was observed in the caustic water bath (pH 9). It was found that the resultant corrosion resistance of the coatings was greatest after post-coating treatment in the water bath of pH 5 and the least for pH 9. Inductively coupled plasma-atomic emission spectroscopy was used to trace small amounts of Zr and Cr elements in the used water baths. A robust chemical titration, adding 1, 5-diaminonaphthalene into the used water baths, revealed that Cr species were only in trivalent form. For AA2024 aluminum alloy, the presence of copper and magnesium elements increases the alloy susceptibility to localized corrosion.1 Therefore, chromate conversion coatings were used to improve the surface resistance against corrosion by a dipping process. However, the toxic hexavalent chromate species in chromate conversion coatings are an ecological concern and, hence, the chromate conversion coating process has been highly regulated by legislation such as the Restriction of Hazardous Substances (RoHS).
3In this regard, trivalent chromium conversion (TCC) coatings are a promising alternative due to the low toxicity of trivalent chromium species.4 Such coating process on AA2024 alloy, driven by the increased pH, consists of surface activation by fluorine attack and coating initiation around second-phase particle and lateral growth on the macroscopic alloy surface. [5][6][7] The freshly-formed coatings have many hydrated channels and the post-treatment in air for 24h can reduce the coating porosity to enhance the corrosion protection while maintaining the hydrated structure. 8 In terms of coating structure, Zr-and Cr-rich oxides comprise the outer layer above a fluoroaluminate layer. 9,10 Notably, a significant amount of fluoride constituent at the coating base was found and it correlated with the locally enhanced corrosion of aluminum substrate, 6 which was assigned with the fluorine attack.
11Fluoride accumulation, especially after prolonged conversion treatment, is a composition challenge for the optimal coating process t...