Trivalent chromium conversion coatings formed on Al and Al-Cu alloys has been investigated using high-resolution, analytical electron microscopy, atomic force microscopy, ion beam analysis, glow discharge optical emission spectroscopy, Raman spectroscopy, X-ray photoelectron spectroscopy, electrochemical impedance spectroscopy, potentiodynamic polarization and electrochemical noise analysis. These coatings on the electropolished Al and sputtering-deposed Al consist of a chromium- and zirconium-rich outer layer and a thinner, aluminium-rich inner layer. Zirconium and chromium are presented in chemical states consistent with ZrO2, Cr(OH)3, Cr2(SO4)3, CrF3 and CrO3 or CrO42-. However, negligible amounts of hexavalent chromium species occurred in both coatings formed in de-aerated solution. On AA2024-T351 alloys, the coating above the second phase particles was thicker than that on the matrix due to the increased localized alkalinity. Moreover, the localized corrosion and copper enrichment of the matrix occurred at the coating base. The presence of copper resulted in a thinner coating at the matrix compared with superpure aluminium. An Fe(III)-containing D30 desmutter can effectively remove the protruded particles generated by alkaline etching. Moreover, a thinner oxide film on the D30-treated surface was evidenced to promote the coating initiation on the matrix. Further, the coating comprised the concentrated zirconium oxyfluorides and decreased contents of aluminium and copper. Coated alloys displayed a significantly enhanced corrosion protection, especially the cathoidc inhibition. In terms of coating post-treatments, the water immersion (40 ºC, pH 5) soon after conversion treatment revealed a simple but effective process to improve the fluoride enrichment in coatings and to enhance corrosion protection of freshly-developed coatings. Increasing concentration of solid-solution copper in sputtering-deposited alloys, in a range of 2, 24, 40 and 64 at.%Cu, significantly promotes the coating growth kinetics and an evident and a thicker corrosion layer by substrate dissolution was observed on Al-40 at.%Cu alloys. In addition, the relationship of copper-rich deposits with Cr(VI) transformation was demonstrated by Raman spectroscopy.

No description available.

Les couches de conversion actuellement utilisées dans l'industrie aéronautique, pour protéger le métal de la corrosion et favoriser l'adhérence de la peinture, contiennent du chrome hexavalent, composé toxique et cancérigène dont l'utilisation va prochainement être interdite par la réglementation européenne REACh. L'une des pistes envisagée pour remplacer ces couches chromatées est l'utilisation de couches de conversion TCP (Trivalent Chromium Protection). Ces travaux portent sur l'étude des couches de TCP et s'attachent à caractériser chaque étape du traitement de surface industriel, incluant les étapes de prétraitement et de post-traitement. Des techniques d'analyse de surface (XPS, ToF-SIMS, AFM, MEB et PM-IRRAS) ont été utilisées pour analyser la composition chimique et la morphologie de la surface après chaque étape du traitement. Cette étude a été réalisée sur un alliage d'aluminium AA 2024-T3, très utilisé en aéronautique pour ses propriétés mécanique, mais présentant une faible résistance à la corrosion. Les résultats obtenus ont notamment mis en évidence que la couche de TCP se forme sur toute la surface de l'alliage (composés intermétalliques et cavités), et ont permis de comprendre comment le post-traitement permet d'améliorer la résistance à la corrosion de la couche de TCP. Ces travaux s'intéressent également à des couches de conversion sans chrome, à base de zirconium, étudiées ici pour servir de point de départ au développement d'une conversion sans chrome qui respecterait les exigences de résistance à la corrosion. / Conversion coatings are used in aerospace industry to protect the metal from corrosion and to promote paint adhesion. Currently, chromate conversion coatings are used, but chromate is toxic and carcinogenic and its use will be forbidden by the European REACh regulation. TCP (Trivalent Chromium Protection) conversion coatings, are considered as a promising alternative to replace chromate conversion coating. This work focuses on the characterisation of the TCP layer and considers each step of the industrial surface treatment, including pre-treatment and post-treatment steps. Surface analytical techniques (XPS, ToF-SIMS, AFM, SEM and PM-IRRAS) were used to analyse the chemical composition and morphology of the surface after each step in the process. This work was done on an aluminium alloy AA 2024-T3, commonly used in the aerospace industry for its good mechanical properties, but poorly resistant to corrosion. The results obtained demonstrate, among other things, that the TCP layer totally covers the surface (intermetallic compounds and cavities) and enable to understand how the post-treatment can improve the corrosion resistance of the TCP coating. This work also focuses on conversion coating based on zirconium, which are studied here to be used as a starting point to develop a new conversion coating without chromium, meeting the corrosion resistance requirement.

As of 21st September 2017, industrial use of hexavalent chromium (Cr(VI)) will, due to its environmental toxicity and carcinogenicity, be restricted by REACH regulations. Saab Aeronautics is therefore shifting anticorrosion surface treatment of aluminum alloys from hexavalent chromium conversion to trivalent chromium (Cr(III)) passivation. The purpose of this thesis is to investigate the characteristics of conversion coatings formed with the passivation chemical SurTec 650V, in order to facilitate transfer to the more environmental friendly alternative. Process parameters, such as pH and immersion time in SurTec 650V passivation baths, have been investigated for passivation of three different aluminum alloys; 2024, 6061 and 7075. The characteristics of the Cr(III) conversion coatings achieved at laboratory scale in the thesis work have been compared with SurTec 650V process in production scale and with Cr(VI) containing Alodine 1200 and Alodine 1500 processes. The impact of varying process parameters have been investigated with goniometry, x-ray photoelectron spectroscopy (XPS), auger electron spectroscopy (AES), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to analyse characteristics of the conversion coatings. Differences in chemical composition on the surface and in depth profile was detected with XPS and AES, respectively and topology of coatings was found to differ for different aluminium alloys and parameter combinations. With TEM, the thickness of the conversion coating was found to be approximately 30-50 nm, which is thinner than the coatings formed with Cr(VI) passivation. Characteristics of coatings formed with Cr(III) passivation is concluded to be very dependent on parameter variation, especially for alloy 2024. Differences also occur between passivation at laboratory and production scale. Further evaluation of the production scale SurTec 650V process and corrosion testing should be performed, and an elaboration of a process control is required before the shift to an environmental friendly passivation process can be completely successful at Saab.

En réponse aux exigences de la réglementation REACH qui prévoit que les substances à base de chrome hexavalent devront être soumises à autorisation dès 2017, les industriels du secteur aéronautique mènent depuis plusieurs années des activités de recherche et développement de nouveaux procédés de traitement de surface moins néfastes pour l’environnement et la santé. Le travail prévu dans le programme de recherche NEPAL (NouvellEs Protections des ALuminiums) s’inscrit dans cette dynamique. Les traitements mettant en oeuvre des composés à base de Cr(VI) sont destinés à disparaître dans un proche avenir ; ainsi de nouvelles formulations ont été développées parmi lesquelles des procédés de conversion à base de chrome trivalent. Le projet de thèse vise à renforcer la robustesse de ces procédés en apportant des éléments de compréhension pour ce qui concerne la tenue à la corrosion des alliages d’aluminium revêtus de couches de conversion au chrome trivalent en relation avec leur état microstructural. Les travaux de thèse ont été développés sur une nuance d’alliage d’aluminium 2024, parmi celles les plus utilisées dans le secteur aéronautique. Plusieurs microstructures ont été considérées dans le but de modifier la distribution en éléments d’alliages majoritaires, le cuivre et le magnésium. La caractérisation fine de la microstructure et l’évaluation de la réactivité des échantillons dans les différents bains de traitement de conversion ont permis de mettre en évidence l’influence de la répartition du cuivre dans l’alliage, élément néfaste pour la croissance des couches de conversion lorsqu’il se trouve sous forme de précipités fins. Finalement, l’étude de deux tôles d’alliage d’aluminium d’épaisseurs différentes met en évidence l’influence de nouveaux paramètres microstructuraux tels que les joints de grains ou la précipitation grossière. Ce travail a été réalisé dans le cadre du projet FUI NEPAL. Le CIRIMAT a été financièrement soutenu par le Ministère de l’Économie et de l’Industrie français (BPI-France), la Région Occitanie Pyrénées-Méditerranée et l’Union Européenne (FEDER/ERDF). / In reply to REACH regulation, which stipulates that hexavalent chromium substance shall besubject to authorization in 2017, manufacturers of aeronautic industries have performed, forseveral years, research and development of new surface treatments less harmful for theenvironment and health. The work planned in NEPAL (NEw Protections for ALminium) researchprogram is part of this large program. The chromate-containing treatments, using Cr(VI)compounds, will disappear in the near future; new formulations have been developed includingtrivalent chromium conversion processes. The thesis project aims to reinforce robustness of theseprocesses by providing data useful for understanding the corrosion resistance of aluminium alloyscoated with trivalent chromium coatings, in relation to their microstructural state. The thesis workwas developed on a 2024 aluminium alloy, among those most used in the aeronautics sector.Several microstructures were considered in order to modify the distribution of major alloyselements, copper and magnesium. The fine characterization of the microstructure and theevaluation of the reactivity of the samples in the different conversion treatment baths highlight theinfluence of the copper distribution in the alloy, this alloying element being detrimental to thegrowth of the conversion coating when it is in the form of fine precipitates. Finally, the study of twosheets of aluminium alloy with different thicknesses reveals the influence of new microstructuralparameters such as grain boundaries or coarse precipitation. This work was performed in theframework of the NEPAL FUI project. CIRIMAT was financially supported by the French Ministry ofEconomy and industry (BPI-France), the Région Occitanie Pyrénées-Méditerranée and theEuropean Union (FEDER/ERDF).

In this thesis work, a high grade chromite concentrate obtained from PinarbaSi, Kayseri region of Turkey was reacted with sulfuric acid solution to determine the optimum conditions of leaching of chromite ores. Conventional methods for producing chromium are still valid in industry. The main process in production includes soda melting and taking it into solution in the form of chemical compounds such as sodium dichromate. Three and six valence states of chromium have importance in production. Trivalent chromium, chrome ore or chromite have no harmful effects. However, compounds of hexavalent chromium show toxic, irritating and corrosive action to people and environment. In the mentioned conventional method, main products consist of hexavalent chromium compounds. In this study, only trivalent chromium remained in the leach solution and did not change to hexavalent state. Obtained product after leaching was chromium(III) sulfate. The maximum extraction of chromium in the absence of perchloric acid was 94.1 % under the conditions of 175 &deg / C, 6 hours and 84.6 wt % sulfuric acid. The maximum extraction of chromium in the presence of perchloric acid was 98.7 % under the conditions of 175 &deg / C, 2 hours, 84.6 wt % sulfuric acid and &frac12 / perchloric acid / chromite ratio. The latter one was also the highest recovery value obtained during the experiments. Moreover, in none of the analyzed samples, appreciable amounts of hexavalent chromium was found during analyses.

Physical, chemical and corrosion properties of a hexavalent chromium conversion coating (CCC) and that of a commercial third generation trivalent chromium system; Tripass LT1500, on zinc electrodeposited steel has been studied. Moreover, the role of additives has been studied to elucidate film formation and corrosion resistance mechanisms. Micro-cracking and self-repair corrosion protection behaviour commonly associated with hexavalent CCCs has also been investigated. Scanning Electron Microscopy (SEM) studies showed that for both hexavalent and trivalent CCCs were in general, flat with a spherical-like structure and in the case of the former microcracked beyond 122 nm conversion coating thickness. In general, the micro-crack pattern observed e.g. a dense crack network, depended upon the underlying zinc substrate morphology. The study has also demonstrated the effect of SEM imaging and prior specimen preparation conditions on hexavalent CCC micro-cracking and blistering. X-ray Photoelectron Spectroscopy (XPS), Auger Electron Spectroscopy (AES) and Infrared (IR) data has indicated that the hexavalent CCC film formation appears to be a electrochemical/sol-gel mechanism given the lack of zinc content at surface and subsurface regions within the conversion coating, presence of H2O and in particular the contribution of Cr(OH)3 as opposed to Cr2O3. An alternative film formation mechanism may exist for trivalent CCC given a higher proportion of zinc at surface and sub-surface regions, IR data analysis indicating that chromium is possibly deposited from a chromium (III) complex ion such as [CrC2O4(H2O)4] + , moreover as Cr(OH)3 and Cr2O3 compounds as indicated by XPS data analysis. The role of cobalt nitrate during film formation is unclear given that cobalt was not detected within the trivalent CCC from XPS and AES data. Electrochemical LPR measurements, polarisation curves and XPS data has shown in general, self-repair corrosion protection properties for hexavalent CCC to be lacking. Instead, it is proposed that the corrosion protection behaviour for hexavalent and trivalent CCC to be barrier. Polarisation curves and LPR data showed that the corrosion resistance performance for trivalent CCC was higher than hexavalent CCC, in general. LPR data showed that the omission of cobalt nitrate and increased addition of sodium molybdate content within the Tripass LT1500 treatment solution formulation was found to overall decrease corrosion resistance within the trivalent CCC. In addition, silica based topcoat and black trivalent CCCs was also investigated and characterised using AES, SEM and LPR. Zinc whiskers was also observed from zinc electrodeposits following exposure to thermal treatment (150°C for 1 h). Elemental analysis and grain pattern investigations failed to help determine the cause of zinc whisker initiation. Zinc whiskers was seen to protrude out of hexavalent and trivalent CCCs, with the latter requiring a longer thermal exposure time.

Chromium exists largely in two oxidation states, namely hexavalent chromium (Cr(VI)) which is carcinogenic, mutagenic to living organisms including humans and trivalent chromium (Cr(III)) which is known to be 1000 times less toxic than Cr(VI). It is therefore desirable in most cases to reduce Cr(VI) to Cr(III). Various studies have been conducted on the Cr(VI) reduction process either in situ or ex situ. However in situ bioremediation using permeable reactive barrier system appears as a potential and attractive technology compared to other in situ technologies. This study was conducted to evaluate the reduction of Cr(VI) to Cr(III) in the short term and regeneration of the biological reactive barrier to achieve continuous long term operation. It was observed from the study that the chromium hydroxide Cr(OH)3(s) precipitated and thus affected the porosity and hydraulic conductivity of the barrier system. It was therefore proposed to implement a regeneration process involving remobilization of precipitated Cr(OH)3 using a dilute acid (0.1% HCl) and recover Cr(III) by electrokinetics. Lowering the pH in the reactor introduced harsh conditions which necessitated the evaluation of a possible culture shift during the regeneration phase. Microbial culture composition during bioremediation and after soil washing was evaluated using a 16S rRNA finger printing method. The microbial barrier was initially inoculated with indigenous bacterial species from dried sludge. The results presented in the phylogenic tree diagrams confirm that, after microbial barrier system operation, the well-known Cr(VI) reducers Bacillus mycoides, Lysinibacillus fusiformis and Micrococcus lylae were the predominant species in the microbial community of the barrier. The microbial barrier system successfully achieved near complete removal of Cr(VI), whereby approximately 75% Cr(VI) removal was achieved within 63 days of operation. The formation of Cr(OH)3(s) was observed in the second week of operation. After 4 weeks of operating the mesocosm under soil washing with 0.1% HCl and electrokinetics remediation with a DC voltage of 50-150 V an increase in total chromium (73%) was observed suggesting that the trapped chromium species in the mesocosm was effectively remobilized with the assumption that Cr(III) had attached to the cathode forming a white-yellow precipitate layer around the cathode. Additionally more than 95% Cr(VI) was transformed to lower toxicity Cr(III) during electrokinetics and soil washing remediation. However, one of the limitations of electrokinetics is near anode focusing effect whereby a layer of precipitate is formed around the anode that lead to the reduction of efficiency of the technology. / Dissertation (MSc)--University of Pretoria, 2014. / lk2014 / Chemical Engineering / MSc / Unrestricted

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第22068号 / 工博第4649号 / 新制||工||1725(附属図書館) / 京都大学大学院工学研究科材料工学専攻 / (主査)教授 邑瀬 邦明, 教授 宇田 哲也, 教授 杉村 博之 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

Content: In this study, equipped charcoal of Ficus carica without impregnation, impregnated with potassium hydroxide (KOH), zinc chloride (ZnCl2) and phosphoric acid (H3PO4) was used for sorption comparison of trivalent chromium from tannery wastewater. The equipped charcoal is characterized before and after used by Fourier transforms infrared spectroscopy (FT-IR). The quantitative elemental analysis is performed of the charcoal using PGT Energy dispersive X-ray spectrometry (EDX). The trivalent chromium sorption efficacy of charcoal was examined investigating charcoal dose, contact time, and relative pH parameters. Batch sorption test revealed that Ficus carica charcoal without impregnation had the maximum sorption capacity of trivalent chromium as depicted Fig. 1a. At the same conditions, trivalent chromium sorption on the Ficus carica charcoal without impregnation, impregnated with potassium hydroxide, zinc chloride and phosphoric acid was 98.9%, 98.8%, 8.9 and 2.5%, respectively. It is noticeable that without impregnation charcoal has a higher sorption capacity. Conversely, impregnation with chemical required cost involvement, time-consuming, long process time, and safe. Fig.1b depicts a shift in the peak intensity which indicated the change of frequency in the functional groups of the charcoal due to chromium adsorption. It indicates various responsible functional groups for the removal of trivalent chromium through Ficus carica charcoal. The trivalent chromium removal efficiency with the Ficus carica charcoal without impregnation was achieved 98.9%. The study could be helpful to design the sorption of trivalent chromium from the tannery wastewater in-house prior to discharge. Take-Away: 1. Without impregnation, Ficus carica charcoal has a better trivalent chromium sorption capacity 2. Trivalent chromium sorption capacity was 98.9%