Hybrid ceramic self-healing coatings for corrosion protection of Al alloys in 3% NaCl solution

This work focuses on the development of sol–gel self-healing coatings for corrosion protection of Al alloys. The use of this method will help to reduce the costs associated with the coating as well as their environmental impact. Coatings were made of a titania matrix loaded with microparticles of poly(vinyl-alcohol) (PVA) containing cerium nitrate as an inhibitor. The PVA particles dissolve in water, so that the cerium nitrate deposits on the Al surface subjected to corrosion. The PVA microspheres were made via the emulsion method, and then loaded with cerium nitrate. The amount of cerium nitrate loaded in the microspheres was evaluated using UV–Vis. As a second step, the titania coating with embedded PVA microspheres loaded with cerium nitrate was deposited on an AA6082 substrate via a sol–gel route. The corrosion resistance of the coated samples was tested in NaCl solution. The coating microstructure, before and after the corrosion tests, was analysed with the use of an SEM (scanning electron microscope) and EDS (energy dispersive spectroscopy), while the corrosion resistance was investigated by EIS (electrochemical impedance spectroscopy). The results showed that the coatings were uniform and compact. They also showed the ability of the hybrid TiO2-based coating to provide protection for the AA6082 from corrosion. The coatings with an induced defect (scratch) were also analysed, and the EIS analysis of the coatings over time showed an increase in resistance, confirming the ability of the coating to heal itself.