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Synthesis and Characterization of CeO2-Al2O3 Nanocomposite Coating on the AA6061 Alloy

In the present study, a thick, uniform and crack-free sol-gel coating embedded with Al2O3-CeO2 nanoparticles was successfully synthesized and deposited on aluminum alloy AA6061 by spin coating method. The coating morphology was characterized by using a scanning electron microscopy coupled with electron diffraction x-ray spectrometer (SEM-EDX), an atomic force microscopy (AFM) and water contact angle measurements. FT-IR spectra were obtained using a Fourier transformation infrared spectrometer. The corrosion resistance of this coating in 3.5 wt.% NaCl solution was evaluated with electrochemical methods including potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS). The stability of the corrosion resistance of this coating was evaluated by immersion in 3.5 wt.% NaCl solution and by exposure to the UV radiation condition. In addition, the adhesion resistance of the coating was also assessed. SEM and AFM results showed that Al2O3-CeO2 nanoparticles dispersed uniformly in the room temperature vulcanized (RTV) silicon rubber matrix and formed a thick and crack-free coating. Both polarization and impedance results reveal that CeO2-Al2O3 nanoparticles embedded silicon rubber coating can improve the corrosion resistance of the AA6061 alloy by more than three orders of magnitude. Meanwhile, the corrosion resistance of this coating was found to be stable under immersion in 3.5 wt.% NaCl solution and UV exposure conditions. However, excessive content of CeO2 nanoparticles in the coating made the coating morphology porous and decreased the thickness of the coating, which resulted in the decrease in the corrosion resistance of the coating.