Viswanathan S. Saji T. S. N. Sankara Narayanan Xiaobo Chen   Editors Conversion Coatings for Magnesium and its Alloys Conversion Coatings for Magnesium and its Alloys Viswanathan S. Saji (cid:129) T. S. N. Sankara Narayanan Xiaobo Chen Editors Conversion Coatings for Magnesium and its Alloys Editors ViswanathanS.Saji T.S.N.SankaraNarayanan InterdisciplinaryResearchCenter SchoolofMechanical,Aerospace forAdvancedMaterials andNuclearEngineering(MANE) KingFahdUniversityofPetroleum UlsanNationalInstituteofScience andMinerals(KFUPM) andTechnology(UNIST) Dhahran,SaudiArabia Ulsan,RepublicofKorea DepartmentofAnalyticalChemistry UniversityofMadras Chennai,India XiaoboChen SchoolofEngineering RMITUniversity Melbourne,VIC,Australia ISBN978-3-030-89975-2 ISBN978-3-030-89976-9 (eBook) https://doi.org/10.1007/978-3-030-89976-9 ©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNatureSwitzerland AG2022 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuseof illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similarordissimilarmethodologynowknownorhereafterdeveloped. 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ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface Magnesium (Mg) and its alloys have attracted significant research attention due to their striking characteristics, such as high specific strength, good thermal and electrical conductivity, vibration and shock absorption, castability, weldability, biodegradability, and biocompatibility. Mg alloys are considered an ideal choice for several technological applications, including automotive, aerospace, defence, electronics, construction, and biomedical. They are promising alternatives to alu- minium alloys in automobile and aerospace applications and biodegradable poly- mers inimplant applications. However, their acceptance is substantially limited by therapidrateofdegradation,whichunderminestheirmechanicalintegrity. SurfacemodificationisaviablechoicetoimprovethecorrosionresistanceofMg alloys. Among the various methods hitherto available, conversion coatings are simple,cost-effective, andamenableforcoatingcomplex-shapedobjectswithhigh conformal uniformity. The conversion coating method involves forming a film/ coatingonthesurfaceofthemetalbychemicalorelectrochemicalreactions.During this treatment, the immediate surface layer of the metal is changed into a film of metallic oxides/other compounds, which are chemically bonded to the surface. A partofthemetalsubstrateisalsoconvertedintoapartofthecoating,whichservesas asupportingbase,improvingtheadhesionofsubsequentlydepositedtopcoatingand providinghighcorrosionresistance. This book is dedicated to chemical and electrochemical conversion coatings of MgandMgalloys.Thebookcoversbothfundamentalsandstate-of-the-artadvance- mentsintheseareas. Thefirsttwochapters(Chaps.1and2)ofPartIprovidefundamentals,categories, mechanisms,andpaintadhesionofchemicalconversioncoatings.Chapters3,4,5, 6, 7, 8, and 9 deliver detailed accounts of various inorganic chemical conversion coatings,includingchromate,phosphate,permanganate,molybdate,vanadate,fluo- ride,carbonate,rare-earths,andzirconium-andtitanium-basedconversioncoatings. The Chapter 10 gives an account of layered double hydroxide coatings, which are highlysignificantforMgalloys. v vi Preface Thefollowingthreechaptersfocusonorganiccompounds–basedchemicalcon- version coatings, viz phytic acid (Chap. 11), tannic/gallic acids (Chap. 12), and hydroxy benzene/phenolic acids and carboxylic/fatty acids (Chap. 13) conversion coatings. ThefirsttwochaptersofPartII(Chaps.14and15)provideinterestingaccountsof self-healing chemical conversion coatings. The section also has chapters on ionic- liquid-basedconversioncoatings(Chap.16)andchitosan-basedconversioncoatings (Chap.17).Thelastchapterofthesection(Chap.18)accountsforsuperhydrophobic surfacesfabricatedbydifferentconversioncoatingmethods. PartIIIofthebookfocusesonelectrochemicalconversioncoatings.Chapters19 and 20elucidate thefundamentalsof electrochemical anodic oxidationand plasma electrolyticoxidationprocesses.Chapter21givesanaccountofrecentapproachesto enhancingthecorrosionresistanceofelectrochemicalconversioncoatedMgalloys, whereasChaps.22and23dealwithmicro-arcoxidation-basedcompositecoatings and biomedical-grade electrochemical conversion coatings. Chapters 24 and 25, respectively, provide concise accounts of various sealing treatments and pre-treatmentsforelectrochemicalconversioncoatings. This book has tried to bring together all the important sections of chemical and electrochemicalconversioncoatingsunderoneroof.Wehopethatthepresentbook willbeahandyreferencetoolforstudentsandresearchersworkingindifferentareas ofcorrosionandsurfacecoatings. Dhahran,SaudiArabia ViswanathanS.Saji Ulsan,RepublicofKorea T.S.N.SankaraNarayanan Melbourne,VIC,Australia XiaoboChen Acknowledgement We are thankful to all the authors for their valued contribution to this book. We would also like to express our gratitude to all those granting us the copyright permissions for reproducing illustrations. We acknowledge King Fahd University of Petroleum and Minerals, Saudi Arabia, for the moral support provided. Our sincerethankstotheSpringerNatureteamforevolvingthisbookintoitsfinalshape. vii Contents PartI Chemical(InorganicandOrganic)ConversionCoatings 1 ChemicalConversionCoatings:Fundamentals andRecentAdvances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Xue-MeiWang,Zhao-QiZhang,Shuo-QiLi,M.BobbyKannan, andRong-ChangZeng 2 InorganicConversionCoatings:Composition,Mechanism, andPaintAdhesion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Yu-RenChu,Yueh-LienLee,andChao-SungLin 3 Chromium-BasedConversionCoatings. . . . . . . . . . . . . . . . . . . . . . 49 JiantaoQiandWenfangLi 4 PhosphateConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . . 73 T.S.N.SankaraNarayanan 5 Permanganate,MolybdateandVanadateConversionCoatings. .. . 113 Ming-ShiSong,Qiu-ShiDeng,RouJunToh,IvanCole, andXiaoboChen 6 FluorideConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 T.S.N.SankaraNarayanan 7 CarbonateConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . . 163 P.MohanSathyaraj,K.Ravichandran, andT.S.N.SankaraNarayanan 8 Rare-EarthConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . 185 ViswanathanS.Saji 9 Zirconium-andTitanium-BasedConversionCoatings. . . . . . . . . . 199 YangeYang ix x Contents 10 LayeredDoubleHydroxideCoatings.. . . . . . . . . . .. . . . . . . . . .. . 211 LiangWu,YonghuaChen,WenhuiYao,XiaoweiDai,TaoWu, YanningChen,JiahaoWu,ZhiyongZhong,andFushengPan 11 PhyticAcidConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . 245 ViswanathanS.Saji 12 TannicandGallicAcidConversionCoatings. . . . . . . . . . . . . . . . . 261 RifangLuo,BoZhang,HaoZhang,LiYang,andYunbingWang 13 HydroxyBenzene/PhenolicAcidsandCarboxylic/FattyAcid ConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 ThiagoFerreiradaConceição,GuilhermeP.Abatti, andCarlosH.M.Beraldo PartII AdvancedApproachesandCoatings 14 Self-HealingChromate-FreeConversionCoatings. .. . . . .. . . . . .. 299 MohammadTabish,JingmaoZhao,MuhammadJunaidAnjum, WangJingbao,andGhulamYasin 15 Self-HealingMechanismsinChemicalConversionCoatings. . . . . . 315 WeiWang,XueFu,andYongFan 16 IonicLiquid-AssistedConversionCoatings. . . . . . . . . . . . . . . . . . . 349 MaríaDoloresAvilés,AnaEvaJiménez,JoaquínArias-Pardilla, andMaríaDoloresBermúdez 17 Chitosan-BasedConversionCoatings. . . . . . . . . . . . . . . . . . . . . . . 377 AdelA.Francis 18 SuperhydrophobicSurfacesbyConversionCoatings. . . . . . . . . . . 395 ViswanathanS.Saji PartIII ElectrochemicalConversionCoatings 19 ElectrochemicalAnodizationofMgAlloys:Fundamentals andState-of-the-ArtProgress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415 QianLi 20 PlasmaElectrolyticOxidationuponMgAlloys: Fundamentals,State-of-the-ArtProgressandChallenges. . . . . . . . 445 VijaySisarwal,ShuaiDong,RouJunToh,KarimGamaleldin, ShrinivasKulkarni,HaiyanLi,IvanS.Cole,JieDong, andXiaoboChen 21 RecentApproachesforEnhancingCorrosionResistance ofPEO/MAO-CoatedMgandItsAlloys. . . . . . . . . . . . . . . . . . . . . 465 M.BobbyKannan,PraneeshLenin,HadisKhakbaz, andRong-ChangZeng Contents xi 22 MAO-BasedCompositeCoatings. . . . . . . . . . . . . . . . . . . . . . . . . . 489 Ai-MengZhang,Pu-ShengSui,Chang-YangLi,Shuo-QiLi, andRong-ChangZeng 23 Biomedical-GradeElectrochemicalConversionCoatings. . . . . . . . 509 DiMei,ShijieZhu,LiguoWang,andShaokangGuan 24 SealingTreatmentsforElectrochemicalConversionCoatings. . . . . 533 SalahSalmanandMohammedK.Gouda 25 Pre-treatmentsofMgAlloysforAnodicOxideCoatings. . . . . . . . . 557 SungmoMoon Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571