Increased Filiform Corrosion Resistance Utilizing a Zirconium-Based Conversion Coating on an Al-Zn-Mg-Cu (AA7075-T6) Alloy as well as Selected Surface Treatments

This study investigates the effect of surface treatment on the formation of Zr-based conversion coatings on AA7075-T6 automotive aluminum alloys and their resistance to filiform corrosion (FFC). Two different surface treatments were studied (A) alkaline-cleaning and (B) alkaline-cleaning with a subsequent acid deoxidation step. A model poly-vinyl butyral (PVB) primer coating was used as the topcoat and specimens were studied with and without the application of a Zr-based conversion coating. Comparisons were made against a control that had no surface treatment. The FFC filament initiation time and propagation kinetics were of particular interest. Scanning electron microscopy (SEM) and x-ray photoelectron spectroscopy (XPS) were used to examine the conversion coating thickness and composition. A bi-layer conversion coating structure is demonstrated and both surface treatments are shown to produce copper enrichment that promotes the formation of the Zr-rich coating. Specimens prepared by alkaline cleaning-only resulted in a substantially thicker oxide layer of which 97% was ZrO2. These specimens provide superior resistance to FFC where the thick Zr-rich oxide is thought to provide a dense blocking layer that prevents electron transfer at the interface. In contrast, the control specimen, exposed only to the copper additions present in the conversion bath is shown to produce an Al oxide-rich layer with only a 33% ZrO2 contribution in the outer layer. The findings demonstrate that the redistribution of functional copper species, that is shown to occur during surface treatment processes, is crucial for the formation of a robust Zr film.

A Review on Adhesively Bonded Aluminium Joints in the Automotive Industry

The introduction of adhesive bonding in the automotive industry is one of the key enabling technologies for the production of aluminium closures and all-aluminium car body structures. One of the main concerns limiting the use of adhesive joints is the durability of these system when exposed to service conditions. The present article primarily focuses on the different research works carried out for studying the effect of water, corrosive ions and external stresses on the performances of adhesively bonded joint structures. Water or moisture can affect the system by both modifying the adhesive properties or, more importantly, by causing failure at the substrate/adhesive interface. Ionic species can lead to the initiation and propagation of filiform corrosion and applied stresses can accelerate the detrimental effect of water or corrosion. Moreover, in this review the steps which the metal undergoes before being joined are described. It is shown how the metal preparation has an important role in the durability of the system, as it modifies the chemistry of the substrate’s top layer. In fact, from the adhesion theories discussed, it is seen how physical and chemical bonding, and in particular acid-base interactions, are fundamental in assuring a good substrate/adhesive adhesion.