Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

Gyoung Gug Jang; Jiheon Jun; Sinchul Yeom; Mina Yoon; Yi Feng Su; John Wade; Michael S. Stephens; Jong K. Keum

doi:10.3390/coatings13050897

Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

Gyoung Gug Jang, Jiheon Jun, Sinchul Yeom, Mina Yoon, Yi Feng Su, John Wade, Michael S. Stephens, Jong K. Keum

Research output: Contribution to journal › Article › peer-review

5 Scopus citations

Abstract

Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO_2, N₂, or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO₂ and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO₂ and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N₂ AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO₂, N₂, and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m², respectively.

Original language	English
Article number	897
Journal	Coatings
Volume	13
Issue number	5
DOIs	https://doi.org/10.3390/coatings13050897
State	Published - May 2023

Funding

This work was supported by the US Department of Energy (DOE) Office of Energy Efficiency and the Renewable Energy Vehicle Technologies Office’s Light Metals Core Program and the DOE Office of Technology Transitions’ Technology Commercialization Fund. The research was conducted at ORNL, which is managed by UT-Battelle LLC for DOE under contract DE-AC05-00OR22725. SEM and XRD were performed at the Center for Nanophase Materials Sciences, which is located at ORNL and sponsored by DOE’s Scientific User Facilities Division. Harry III Meyer collected XPS data. Peter Yancey (Atmospheric Plasma Solutions, 11301 Penny Road, Cary, NC 27518, USA) supported the production of atmospheric plasma-treated Mg alloy samples. This research used resources of the National Energy Research Scientific Computing Center; a DOE Office of Science User Facility supported by the Office of Science of the U.S. Department of Energy under Contract No. DE-AC02-05CH11231 using NERSC award BES-ERCAP0024568.

Funders	Funder number
DOE Office of Technology Transitions’ Technology Commercialization Fund
Office of Energy Efficiency and the Renewable Energy Vehicle Technologies Office’s Light Metals Core Program
U.S. Department of Energy	DE-AC02-05CH11231, BES-ERCAP0024568
Office of Science
UT-Battelle	DE-AC05-00OR22725
National Energy Research Scientific Computing Center

Keywords

Mg alloys
atmospheric pressure plasma
coating adhesion
corrosion resistance

Access to Document

10.3390/coatings13050897

Cite this

@article{d9a041aa97814d13a10b3ed39b1df45a,

title = "Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance",

abstract = "Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO2, N2, or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO2 and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO2 and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N2 AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO2, N2, and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m2, respectively.",

keywords = "Mg alloys, atmospheric pressure plasma, coating adhesion, corrosion resistance",

author = "Jang, {Gyoung Gug} and Jiheon Jun and Sinchul Yeom and Mina Yoon and Su, {Yi Feng} and John Wade and Stephens, {Michael S.} and Keum, {Jong K.}",

note = "Publisher Copyright: {\textcopyright} 2023 by the authors.",

year = "2023",

month = may,

doi = "10.3390/coatings13050897",

language = "English",

volume = "13",

journal = "Coatings",

issn = "2079-6412",

publisher = "MDPI",

number = "5",

}

TY - JOUR

T1 - Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

AU - Jang, Gyoung Gug

AU - Jun, Jiheon

AU - Yeom, Sinchul

AU - Yoon, Mina

AU - Su, Yi Feng

AU - Wade, John

AU - Stephens, Michael S.

AU - Keum, Jong K.

PY - 2023/5

Y1 - 2023/5

N2 - Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO2, N2, or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO2 and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO2 and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N2 AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO2, N2, and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m2, respectively.

AB - Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO2, N2, or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO2 and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO2 and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N2 AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO2, N2, and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m2, respectively.

KW - Mg alloys

KW - atmospheric pressure plasma

KW - coating adhesion

KW - corrosion resistance

UR - http://www.scopus.com/inward/record.url?scp=85160425045&partnerID=8YFLogxK

U2 - 10.3390/coatings13050897

DO - 10.3390/coatings13050897

M3 - Article

AN - SCOPUS:85160425045

SN - 2079-6412

VL - 13

JO - Coatings

JF - Coatings

IS - 5

M1 - 897

ER -

Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

Abstract

Funding

Keywords

Access to Document

Other files and links

Fingerprint

Cite this