Electrochemical corrosion behavior of magnetron-sputtered aluminum films on carbon fiber reinforced polymer surfaces in 3.5 % NaCl solution
Year: 2025
Type: article
Abstract: This study aimed to investigate the magnetron sputtering process of Al films on epoxy-based composite materials, assess the influence of outgassing from the epoxy resin, a key matrix component, on the film performance, and establish the relationship between film crystalline structure, micro-morphology, and corrosion resistance. The results reveal that the Al film was primarily characterized by the Al (220) plane peak at lower sputtering currents. As the sputtering current increased, the peak intensity of the Al (111) plane and grain size grew, and grain boundaries became more distinct. Nonetheless, the release of impurity gases from the epoxy resin led to a general presence of amorphous Al 2 O 3 structures in the film. Excessive sputtering currents or prolonged coating times brought about an increase in the Al 2 O 3 phase and a reduction in Al crystallinity. Additionally, Electrochemical impedance and Potentiodynamic polarization curves were conducted in a 3.5 wt.% NaCl solution suggests that processes with higher Al crystallinity and stronger Al (111) plane peaks demonstrated better corrosion resistance, processes with finer grains or predominantly Al (220) plane peaks were prone to pitting initiation, and processes with low Al crystallinity and enriched Al 2 O 3 phases exhibited severe pitting. The film with a thickness of 10-15 μm made by current intensity of 5-6 A has the strongest corrosion resistance.
Authors: Yang Yang, Kaiye Xiao
Language: English
Subfield: Materials Chemistry
Field: Materials Science
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,670
OpenAlex ID: W4414445103