Aluminium alloys are frequently pre-treated by a conversion coating before application of an organic coating in order to improve the corrosion resistance and adhesive properties of the surface and the corrosion resistance provided by the system. Chromate-containing conversion coatings are commonly used for this purpose. However, legislation limits future use of hexavalent chromium compounds due to their toxic and carcinogenic nature. Therefore, alternative, so-called chromium-free conversion coatings are being developed that are more environmentally-compliant.The purpose of the present work has therefore been to contribute to a better understanding of how the aluminium substrate affects the formation and properties of conversion coatings for adhesive bonding. In particular, a chrome-free zirconium-based conversion treatment process has been investigated as a possible replacement for conventional chromate conversion treatment. The influence of the conversion time on the thickness of the formed layer on pure aluminium was investigated using complementary surface analytical techniques. The conversion time was varied between 30 and 600 seconds.In this study, the structure and composition of zirconium-based chromium-free conversion coatings on magnetron sputtered superpure aluminium and a range of aluminium-copper alloys were characterised as a function of immersion time in the aqueous conversion bath to understand the mechanism of coating formation and protection. However, the presence of copper significantly influences the coating development and ultimately the performance of the conversion coatings formed on binary copper-containing aluminium alloys.The morphology and composition of the coatings have been probed using transmission electron microscopy, Rutherford backscattering spectroscopy and glow discharge optical emission spectroscopy, with loss of substrate through growth of the conversion coating also quantified. A comparison of the RBS spectra obtained for the superpure aluminium specimens after different immersion times revealed that zirconium (Zr) and oxygen (O) peaks were wider for longer immersion times, indicating thickening of the coating with increased immersion times. Thus, increasing the immersion time resulted in an increase in coating thickness but little change in coating composition occurred as determined by the RBS RUMP simulations. Alloying decreases the coating thickness, as well as metal consumption. Here, aspects of the corrosion behaviour of superpure aluminium and aluminium-copper alloys were also considered using electronoptical, electrochemical and surface analytical probing. The influence that short and prolonged treatment times exert on the performances of such conversion coating is discussed. The conversion coating formed after 60 s and 180 s of immersion in the zirconium-based conversion coating bath provide good corrosion resistance which can be attributed to the high stability of the compounds that constitute the surface oxide layer, and good adhesion properties.

The hot forming-quenching (HFQ) process has introduced grains and subgrain growth, accompanied with modification of the intermetallic particle distribution in AZ31 magnesium alloys. Each region of the HFQ component represents significant grain structure variation and surface conditions that contributed to the corrosion susceptibility. The homogeneous grain structure significantly ruled the corrosion propagation features by filiform-like corrosion. Immersion of AZ31 alloys in 3.5 wt.% NaCl indicated higher corrosion rate of HFQ TRC (corrosion rate: 10.129 mm/year), a factor of 10 times, higher than the rolled alloy (corrosion rate: 0.853 mm/year) and a factor of 2 times, higher than the corrosion rate of MCTRC alloy (corrosion rate: 5.956 mm/year). Much lower corrosion rate was indicated in the as-cast TRC and MCTRC alloys, compared to the alloys after HFQ process that revealed the contribution of network or continuous distribution of β-Mg17Al12 phase particles to reduce the corrosion driven in chloride solution. In contrast, discontinuous distribution of cathodic β-Mg17Al12 phase particles increases the corrosion rate of HFQ TRC alloy by promoting the cathodic reaction and intense filament propagation resembling the coarse interdendritic and grain boundaries attack. The presence of high population densities of cathodic Al8Mn5 particles in HFQ rolled AZ31B-H24 alloy significantly reduced the corrosion driven for intense corrosion attack on the rolled alloy. The surface preparation by mechanical grinding process induced MgO and Zn-enrichment layer, accompanied with near surface deformed layer that consisted of nanograins in the range size of 40 to 250 nm. The grinding process refined the surface by removing the cutting damage and marks that formed during the thermomechanical process and led to stable potential of the HFQ AZ31 alloys, in the range of -1.59 to -1.57 V, during open circuit potential (OCP) measurement. The surface regularity with grinding path causing the filament to propagate following the grinding direction. The as-received surface contained many cutting damages and deep scratch marks from the rolling and casting processes that could introduce many corrosion initiation sites. The absence of the grinding direction on the as-received surface could control intense corrosion susceptibility, due to the non-linear filament propagation. The surface irregularity on chromic acid cleaned surface of HFQ rolled AZ31B-H24 alloy also contributed to low corrosion potential of the rolled alloy during OCP and potentiodynamic polarization measurement.

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The filiform-like corrosion of Magnesium (Mg) alloys AZ31B and AM30 was investigated with electrochemical and microanalytical techniques. Potentiodynamic polarization testing and scanning vibrating electrode technique (SVET) measurements confirmed the “differential electrocatalytic” mechanism previously reported for filiform and filiform-like corrosion on pure Mg and AZ31B. Transmission electron microscopy (TEM) and Auger electron spectroscopy (AES) revealed that the MgO corrosion filaments on both alloys were likely a product of the direct reaction of Mg and water (H2O), responsible for the rapid hydrogen (H2) evolution observed at the propagating corrosion fronts. TEM analysis also revealed through-thickness cracks and noble intermetallic particles within the corrosion filaments and noble metal enrichment at the corrosion filament/metal interfaces, which were proposed to play significant roles in the cathodic activation of the corrosion filaments. The higher susceptibility of the AZ31B alloy to cathodic activation versus AM30 suggested that Zinc (Zn) has a detrimental effect on the resistance of Magnesium-Aluminum-Zinc (Mg-Al-Zn) alloys to filiform and filiform-like corrosion. / Thesis / Master of Applied Science (MASc)

La capacité à percevoir des courants dans un fluide s'est développée chez de nombreuses espèces animales, dans des contextes écologiques très variés qui couvrent aussi bien les interactions proies-prédateurs, la sélection sexuelle ou l'orientation dans un environnement. Parmi ces espèces animales, les grillons détectent les courants d'air générés notamment lors de l'attaque de leurs prédateurs à l'aide de deux organes appelés "cerques", situés à l'arrière de leur abdomen et recouverts de poils mécano-sensoriels. Ces senseurs sont considérés comme les détecteurs les plus sensibles du monde animal. Il leur suffit de capter l'énergie d'un dixième d'un photon pour déclencher un potentiel d'action au niveau du neurone sensoriel. Ce manuscrit présente à la fois le développement des outils de mesures sans contact adaptés à ces questions d'écologie sensorielle ainsi que les méthodes numériques simulant les processus physiques à l'oeuvre. L'étude du fonctionnement des senseurs a nécessité l'adaptation des méthodes de mesures non intrusives de très grande précision tel que la Vélocimétrie par Imagerie de Particules (PIV). La couche limite oscillante dans laquelle évoluent les poils a été visualisée et a servi à déterminer la réponse de poils modélisés par des systèmes oscillatoires du second ordre. Le couplage visqueux entre poils a été lui aussi caractérisé en adaptant la PIV à des mesures à très petites échelles sur des poils biomimétiques micro-electro-mécanique (MEMS). Les mesures des perturbations générées lors des attaques d'araignées, principales prédatrices des grillons, nous ont aidé à valider des modélisations numériques, réalisées à l'aide des techniques de dynamique des fluides computationnelles (CFD) par résolution des équations de Navier Stokes via la méthode des éléments finis (FEM). La mise au point et l'utilisation de techniques de métrologie optique en dynamique des fluides semi-visqueux et l'analyse des données nous permettent de revisiter la sensibilité extrême du système sensoriel du grillon et de placer ces mesures dans un contexte plus large, d'écologie sensorielle. En particulier, nous montrons que ces soies sont placées en groupe compact et exercent entre elles un fort couplage aérodynamique visqueux, qui réduit fortement leur sensibilité "de groupe". Ce fort couplage interroge l'intérêt d'avoir des récepteurs aussi performants individuellement, s'ils perdent leur sensibilité lorsqu'ils fonctionnent en réseau. Finalement, les réactions des poils à des mouvements de fluides générés par un piston mimant les attaques réelles d'araignées ont pu être déterminées à l'aide d'une caméra rapide, puis simulées et validées après avoir développé un modèle mécanique du poil répondant à des stimuli transitoires. / Flow sensing is used by a vast number of animals in various ecological contexts, from preypredator interactions to mate selection, and orientation to flow itself. Among these animals, crickets use hundreds of filiform hairs on two cerci as an early warning system to detect remote potential predators. Over the years, the cricket hairs have been described as the most sensitive sensor in the animal kingdom. The energy necessary for the emission of an action potential by its sensory neuron was estimated to be a tenth of the energy of a photon. This PhD thesis aims to describe recent technological advances in the measurement and model of flows around biological and artificial flow sensors in the context of organismal sensory ecology. The study and understanding of the performance of sensory systems requires a high spatial precision of non-intrusive measurement methods. Thus, non-contacting measurement methods such as and Particle Image Velocimetry (PIV), originally developed by aerodynamics and fluid mechanics engineers, have been used to measure flows of biological relevance. The viscous oscillatory boundary layer surrounding filiform hairs has been visualized and used as input to model the mechanical response of these hairs, described as second order mechanical systems. The viscous hydrodynamic coupling occurring within hair canopy was also characterized using PIV measurements on biomimetic micro-electro-mechanical systems (MEMS) hairs, mimicking biological ones. Using PIV, we have also measured the air flow upstream of hunting spiders. We prove that this flow is highly conspicuous aerodynamically, due to substantial air displacement detectable up to several centimeters in front of the running predator. This disturbance of upstream air flows were also assessed by computational fluid dynamics (CFD) with the finite elements method (FEM). The development of non-intrusive measurement and CFD methods and their application to the analysis of the biological flow involved in cricket sensory ecology allowed us to revisit the extreme sensitivity of cricket filiform hairs. We predicted strong hydrodynamic coupling within natural hair canopies and we addressed why hairs are packed together at such high densities, particularly given the exquisite sensitivity of a single hair. We also proposed a new model of hair deflection during the arrival of a predator, by taking into account both the initial and long-term aspects of the flow pattern produced by a lunging predator. We conclude that the length heterogeneity of the hair canopy mirrors the flow complexity of an entire attack, from launch to grasp.