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Polymer-infiltration-pyrolysis (PIP) inspired hydrophobic nano-coatings for improved corrosion resistance

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Abstract

Nature-inspired hydrophobic coatings have caught great attention due to their repellency to corrosive mediums and less interaction between substrate and chemical species. Aluminum is considered one of the metals having superior properties against corrosion due to passive film formation. It can further be enhanced by the formation of a hierarchical structure through 2nd step anodization. In previous studies, carbon infiltrated in anodized alumina pores through CVD method (chemical vapor deposition) was quite an expensive and complex method. The fabrication of anti-corrosion coating with a simple and cost-effective method will broaden the aluminum alloy applications in the chemical, petrochemical, and aerospace industries, etc. In this research, pyrolytic carbon is infiltrated in porous alumina through pyrolysis at three different temperatures for 30 min under a controlled environment by using flaxseed oil as a source of carbon. The surface morphology along with chemical composition and wetting angle were studied through SEM (Scanning Electron Microscope), EDX (Energy Dispersive X-ray Spectroscopy), and Sessile drop method. It was found that both low surface energy and high roughness participate in increasing the wetting angle. Nanocomposite coating having maximum carbon content has a maximum wetting angle with inorganic liquid. Based on the electrochemical behavior determined by Tafel and EIS (Electrochemical Impedance Spectroscopy) analysis, the hydrophobic coating containing 57.5% carbon content having a contact angle of 95° exhibits maximum corrosion resistance of around 28,000 kohm as compared to anodized aluminum having minimum corrosion resistance of around 4.26 kohm. The results and the cost-effective method could be beneficial in aircraft parts as well as in aeronautical applications.

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Acknowledgements

I am very thankful to Allah Almighty without Him nothing is impossible. I am thankful to my parents and Metallurgical & Materials Engineering Department UET Lahore, Pakistan, especially Dr. Ing. Furqan Ahmed and Mr. Hayat.

Funding

This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors.

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Authors and Affiliations

  1. Department of Metallurgical & Materials Engineering (MME), Faculty of Chemical, Metallurgical & Polymer Engineering, University of Engineering & Technology (UET) Lahore, Lahore, 54890, Pakistan

    Mavia Rashid, Ehsan Ul Haq & Amjad Ali

  2. Department of Material Science and Engineering, Ghulam Ishaq Khan Institute of Engineering Sciences and Technology, Topi, 24360, Khyber Pakhtunkhwa, Pakistan

    Muhammad Ramzan Abdul Karim & Waseem Shehzad

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  1. Mavia Rashid
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  2. Ehsan Ul Haq
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  3. Muhammad Ramzan Abdul Karim
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  4. Waseem Shehzad
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  5. Amjad Ali
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Contributions

MR: Conceptualization, Methodology, Software, Data curation, Writing Original draft preparation. Dr. EUH: Supervision, Visualization, Investigation, Writing- Reviewing, and Editing. Dr. RAK: Software and Validation. Mr. WS: Software, Conceptualization. Mr. AA: Conceptualization, Methodology.

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Correspondence to Ehsan Ul Haq.

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Rashid, M., Ul Haq, E., Abdul Karim, M.R. et al. Polymer-infiltration-pyrolysis (PIP) inspired hydrophobic nano-coatings for improved corrosion resistance. J Mater Sci 59, 828–846 (2024). https://doi.org/10.1007/s10853-023-09226-4

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