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Layered double hydroxides (LDH) are a class of anionic clay with alternating layers of positive and negative charge. A metal hydroxide layer with divalent and trivalent metals with a positive charge is complemented by an interlayer region containing anions and water with a negative charge. The anions can be exchanged under favorable conditions. Hydrotalcite (Mg6Al2(OH)16[CO3]·4H2O) and other variations are naturally occurring minerals. Synthetic LDH can be prepared as a powder or film by numerous methods. Synthetic LDH is used in electrode materials, adsorbents, nuclear waste treatment, drug delivery systems, water treatment, corrosion protection coatings, and catalysis. In this dissertation Zn-Al-NO3 derivatives of zaccagnaite (Zn4Al2(OH)12[CO3]·3H2O) are electrochemically synthesized as films and applied to sensing and corrosion resistance applications. First, Zn-Al-NO3 LDH was potentiostatically electrosynthesized on glassy carbon substrates and applied to the electrochemical detection of gallic acid and caffeic acid in aqueous solutions. The modified electrode was then applied to the detection of gallic acid in green tea samples. The focus of the work shifts to corrosion protection of stainless steel. Modified zaccagnaite films were electrodeposited onto stainless steel in multiples layers to reduce defects caused by drying of the films. The films were deposited using a step potential method. The corrosion resistance of the films in a marine environment was investigated while immersed in 3.5 wt.% NaCl environments. Next modified zaccagnaite films were potentiostatically electrodeposited onto stainless steel followed by a hydrophobization reaction with palmitic acid in order to prepare superhydrophobic (>150° contact angle) surfaces. Each parameter of the film synthesis was optimized to produce a surface with the highest possible contact angle. The fifth chapter examines the corrosion resistance of the optimized superhydrophobic film and a hydrophobic film. The hydrophobic film is prepared using the same procedure as the superhydrophobic film except for a difference in electrodeposition potential. The corrosion resistance of these films is investigated in a simulated marine environment (3.5 wt.% NaCl) for short and extended durations. The last chapter summarizes the previous chapters and suggests future directions for this work.

As it becomes more important to replace fossil fuels with alternative fuels, biofuels like ethanol are becoming more commercially used. The increased use of ethanol brings good influences such as lower impact on the environment. However, the use of ethanol can also bring negative effects regarding corrosion of metals. In the automotive industry aluminium has been seen affected by a novel very aggressive corrosion phenomenon, alcoholate corrosion. This master thesis investigation has investigated the effect of a few parameters of importance for alcoholate corrosion; water, temperature, time and pressure. The aluminium alloys AA6063 and A380 have been investigated and the capacity of five different surface treatments of AA6063 has been tested to observe if they inhibit the effect of alcoholate corrosion.   Throughout the experiments the water dependence of alcoholate corrosion has showed to be of large importance for the corrosion process. An increase in water content will postpone the start of alcoholate corrosion or prevent corrosion to occur.  A correlation between temperature and time has been observed. Higher temperatures results in a shorter time period of exposure before alcoholate corrosion occurs, and vice versa. The effect of different pressures was investigated and showed no effect on alcoholate corrosion when using pressurisation with the inert nitrogen gas.   All surface treatments revealed a capacity to protect the aluminium alloy against alcoholate corrosion to different extent. The electroless nickel plating seemed to prevent alcoholate corrosion while the Keronite coating seemed more sensitive to this form of corrosion.

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Indiana University-Purdue University Indianapolis (IUPUI) / There are three parts in this work centered on the catalyst layer of Polymer Electrolyte Fuel Cell (PEFC) in this thesis. The first part is for making best MEA structure. One of the major aims of this investigation is to understand the micro-structural organization of ionomer particles and Pt/C aggregates dispersed in a catalyst ink. The dispersion of Nafion® ionomer particles and Pt/C catalyst aggregates in liquid media was studied using ultra small angle x-ray scattering (USAXS) and cryogenic TEM technologies. A systematic approach was taken to study the dispersion of each component (i.e. ionomer particles and Pt/C aggregates) first, then the combination, last the catalyst ink. A multiple curve fitting was used to extract the particle size, size distribution and geometry from scattering data. The results suggests that the particle size, size distribution and geometry of each system are not uniform, rather, vary significantly. The results also indicate that interaction among components (i.e. ionomer particles and Pt/C aggregates) exists. The cryogenic TEM, by which the size and geometry of particles in a liquid can be directly observed, was used to validate the scattering results, which shows the excellent agreement. Based on this study, a methodology of analyzing dispersion of Pt/C particles, Nafion® particles in a catalyst ink has been developed and can serve as a powerful tool for making a desired catalyst ink which is a critical step for making rational designed MEA. The carbon corrosion process is the second part of the thesis. The carbon corrosion process of low–surface-area Pt/XC72 and high-surface-area Pt/BP2000 was investigated xi using an developed accelerated durability testing (ADT) method under simulated fuel cell conditions (a Rotating Disk Electrode (RDE) approach). Compared with the complex MEA system, this innovated approach using RDE can simply focus on carbon corrosion process and avoid the use of MEA in which many degradation/corrosion processes simultaneously occur. It was observed that different carbon corrosion processes resulted in different performance (electrochemical active surface area, mass activity and double layer capacity) decay of catalysts. The corrosion process was studied using TEM. It was found that in the case of Pt/XC72, major corrosion occurred at the center of the Pt/XC72 particle, with some minor corrosion on the surface of the carbon particle removing some amorphous carbon black filaments, while in the case of Pt/BP2000, the corrosion started on the surface. The understanding of carbon corrosion process provides the guidance for making high corrosion resistance catalysts to increase the durability performance of PEFC. Based on the second work, XC72 carbon blacks were etched using steam under different time and used as a new high corrosion resistance catalysts support for the oxygen reduction reaction. TEM results show that the center part of the XC72 particle was more easily etched away. XRD results show that the 002 and 10 peaks of the XC72 based samples are initially sharp, but then broaden during the corrosion process. TEM results of Pt particles show that the steam etching can improve dispersion uniformity of Pt nanoparticles on the surface of carbon support and reduce the Pt particles size. Electrochemical characterization results show that the mass activity of etched carbon black for 1 hour was 1.3 and 34 times greater than that of the carbon blacks etched for 3h and that of carbon blacks non-ecthed. ECSA of the carbon blacks was also significantly increased after etching. MEA test showed after 45 hours testing, the performance MEA with steam etching 1 hour XC72 based catalyst decreases much less than the MEA with commercial catalyst. Clearly, steam etching is a simple and efficient method to increase the performance and durability of the fuel cells catalysts.

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