Derek Beving, Cory O'Neill, and Yushan Yan, University of California; Nicole Anderson, NAWCWD
Zeolites are microporous crystalline aluminosilicates with uniform and molecular sized pores. They are non-toxic and have been explored for medical applications. We have been investigating the application of zeolite films as chromium-free protective coatings on aluminum alloys. We have shown that as-synthesized organic template containing high-silica-zeolite (HSZ) MFI coatings on AA-2024-T3 are non-porous and have excellent corrosion resistance in strong acids, bases, and pitting aggressive media. We have demonstrated that high silica coatings including MFI, BEA and MTW are all good corrosion resistant coatings. We have also shown that the in-situ crystallization coating deposition process we use can coat surfaces of complex shapes and in confined spaces. We successfully expanded our investigations to include other aluminum alloys (6061-T4, 5052-H32, 7075-T6) and steels (SS304-2b, S1008, S4130). We were able to use one simple pretreatment and a single zeolite formulation on all aluminum alloys and steels to synthesize MFI coatings. Corrosion protection was measured by DC polarization in several corrosive media. DC polarization in 5 wt% NaCl is used as a screening diagnostic prior to salt-fog testing. Salt-fog accelerated weathering tests were performed according to ASTM 117-B on scribed and non-scribed HSZ MFI coated 2024-T3. The non-scribed HSZ MFI coated 2024-T3 panels had no observable corrosion after more than 2000 hrs continuous salt fog exposure. The scribed HSZ-MFI coated 2024-T3 panels exhibited no delamanation of the zeolite coating after 1000 hrs continuous salt fog exposure and corrosion was limited to the scribe. The compatibility between zeolite coatings with primer and topcoat systems has been investigated. A coating system of zeolite-primer (chromated) and zeolite-primer (chromated)-topcoat passed 3100 hrs continuous salt fog exposure with no observable corrosion and delamination. Detailed preparation procedure of the zeolite coatings and their corrosion resistance will be presented, and the future directions of this research will be discussed.