Monday, December 3, 2007 - 2:00 PM

Influence of Processing Parameters on Cerium Based Conversion Coatings

Bill Fahrenholtz, Matthew O'Keefe, Thomas O'Keefe, and Paul Yu, University of Missouri Rolla

A number of different environmentally friendly pretreatments and material systems are currently being investigated to replace hexavalent chromate compounds as corrosion inhibitors for metals. Ideally, the environmentally benign pretreatments will provide the same corrosion protection and compatibility with subsequent organic coatings as the existing chromate based conversion coatings as well as be readily integrated into DoD and OEM manufacturing operations. Cerium based conversion coatings have the potential to replace Cr(VI) conversion coatings in many applications and can be deposited by electrolytic, immersion, and spray methods. However, the processing conditions during substrate preparation, cerium oxide formation, and post-deposition treatment influence the morphology, phase, deposition rate, uniformity, and overall quality of the coatings, all of which impact the corrosion performance during neutral salt spray testing. Results from studies that have been conducted to identify processing parameters that significantly influence coating formation on high strength aluminum alloys will be described. Combined with fundamental studies on cerium oxide/hydroxide precipitation from aqueous solutions, materials characterization, and electrochemical testing, a deposition sequence has been developed and will be presented. Correlation between key processing parameters, such as surface preparation, the ratio of cerium ions to hydrogen peroxide and the use of additives in the deposition solution, and post-deposition treatment methods, and corrosion performance have been identified that provide insight into improving the overall effectiveness of cerium based conversion coatings.