The effect of alkaline etching time on the anticorrosion performance of vanadia film formed on high strength AA2024 in chloride media

Corrosion performance, morphology, and electrochemical characteristics of vanadia-based conversion coatings on high strength aluminum AA2024-T3 alloy were examined as a function of alkaline etching time prior to vanadia treatment. Corrosion resistance and coating performance improved after etching in an alkaline solution for 10 min followed by vanadia treatment at room temperature. Electrochemical impedance spectroscopy and polarization testing correlated to macro- and microscopic surface examination and visual inspection. Proper etching of aluminum AA2024-T3 panels in alkaline solution prior to vanadia coating is a time dependent and considers a critical step for improved coating performance and materials durability. Results showed that the optimum alkaline etching time prior to vanadia treatment was 10 min which offers the best resistance to localized corrosion attack in NaCl solution. Alkaline etching for 10 min has an important role in increasing the number of OH groups on the aluminum surface, contributing to the adhesion of the vanadia-rich aluminum oxide layer by promoting covalent bonding. Based on these results, processes active during alkaline etching are kinetically dependent and strongly influenced by etching time.