Improvement of Mechanical and Corrosion Properties of Commercially Pure Titanium Using Alumina PEO Coatings

In this study, the surface of commercially pure titanium (Cp-Ti) was covered by a 21–95 µm-thick aluminum oxide layer using plasma electrolytic oxidation. Coating characterization revealed the formation of nodular and granular α- and γ-Al2O3 phases with minor amounts of TiAl2O5 and Na2Ti4O9 which yielded a maximum 49.0 GPa hardness and 50 N adhesive critical load. The corrosion resistance behavior in 3.5 wt.% NaCl solution of all plasma electrolytic oxidation (PEO) coatings was found to be two orders of magnitude higher compared to bare Ti substrate.

Facile Route to Effective Antimicrobial Aluminum Oxide Layer Realized by Co-Deposition with Silver Nitrate

The emergence and spreading of the SARS-CoV-2 pandemic has forced the focus of attention on a significant issue: the realization of antimicrobial surfaces for public spaces, which do not require extensive use of disinfectants. Silver represents one of the most used elements in this context, thanks to its excellent biocidal performance. This work describes a simple method for the realization of anodized aluminum layers, whose antimicrobial features are ensured by the co-deposition with silver nitrate. The durability and the chemical resistance of the samples were evaluated by means of several accelerated degradation tests, such as the exposure in a salt spray chamber, the contact with synthetic sweat and the scrub test, highlighting the residual influence of silver in altering the protective behavior of the alumina layers. Furthermore, the ISO 22196:2011 standard was used as the reference protocol to set up an assay to measure the effective antibacterial activity of the alumina-Ag layers against both Gram-positive (Staphylococcus aureus) and Gram-negative (Escherichia coli) bacteria, even at low concentrations of silver. Finally, the Ag-containing aluminum oxide layers exhibited excellent antimicrobial performances also following the chemical–physical degradation processes, ensuring good durability over time of the antimicrobial surfaces. Overall, this work introduces a simple route for the realization of anodized aluminum surfaces with excellent antibacterial properties.

Al2O3/WS2 Surface Layers Produced on the Basis of Aluminum Alloys for Applications in Oil-Free Kinematic Systems

The article presents the results of an aluminum oxide layer doped with monolayer 2H tungsten disulphide (Al2O3/WS2) for applications in oil-free kinematic systems. The results concern the test carried out on the pneumatic actuator operational test stand, which is the actual pneumatic system with electromagnetic control. The cylinders of actuators are made of Ø 40 mm aluminum tube of EN-AW-6063 aluminum alloy which is used in the manufacture of commercial air cylinder actuators. The inner surfaces of the cylinder surfaces were covered with an Al2O3/WS2 oxide layer obtained by anodic oxidation in a three-component electrolyte and in the same electrolyte with the addition of tungsten disulfide 2H-WS2. The layers of Al2O3 and Al2O3/WS2 obtained on the inner surface of the pneumatic actuators were combined with a piston ring made of polytetrafluoroethylene with carbon (T5W) material and piston seals made of polyurethane (PU). The cooperation occurred in the conditions of technically dry friction. After the test was carried out, the scanning electron microscopy with energy dispersive spectroscopy (SEM/EDS) analysis of the surface of the cylinder bearing surfaces and piston seals of the pneumatic cylinders was performed. The analysis revealed the formation of a sliding film on the cylinder surface modified with tungsten disulfide, as well as on the surface of wiper seals. Based on the SEM/EDSM tests, it was also found that the modification of the Al2O3 layer with tungsten disulfide contributed to the formation of a sliding film with the presence of WS2 lubricant, which translated into smooth cylinder operation during 180 h of actuator operation. The cylinder with the unmodified layer showed irregular operation after approximately 70 h thereof.

Influence of Alloying Elements on the Mechanical Properties of Anodized Aluminum and on the Adhesion of Copper Metallization

The active development of the power electronics market and a constant increase in the prices of components require new materials and approaches, including a power module packaging technology. The use of aluminum instead of copper in the power module baseplate is an interesting and promising solution. The insulated metal baseplate is one of the most extensively developed technologies nowadays. The object of this study is an insulated metal substrate based on anodized aluminum. The main goal of the article is the comparison of copper topology adhesion to an anodized aluminum oxide layer formed on different aluminum alloys with aluminum content of at least 99.3 wt %. Peel test and pull-off adhesions showed a twofold difference for both aluminum alloys. The high ordered defect-free anodized alumina formed on alloys with copper content of 0.06 wt % had a mean pull-off adhesion of 27 N/mm2 and hardness of 489 HV. In the case of the alloy with copper content of around 0.15 wt %, it had hardness of 295 HV and a mean pull-off adhesion of 12 N/mm2. The results of our microstructure investigation showed that anodized alumina based on alloys with copper content of around 0.15 wt % is fragile due to spherical holes. Summing up the results, it can be concluded that not all initial impurities are critical for anodized alumina, but some, specifically copper, dramatically decreased the mechanical properties of anodized alumina.

Sn-Aided Joining of Cast Aluminum and Steel Through a Compound Casting Process

Obtaining a strong bond between aluminum and steel is challenging due to poor wettability between aluminum melt and steel and brittle intermetallic phases forming in the interface. In this research, a novel coating method, namely hot dipping of Sn, has been developed to treat the steel insert surfaces. Results show that without preheating the mold or Sn-coated insert, a thin, crack-free, and continuous metallurgical bonding layer was achieved in the A356 aluminum/steel compound castings. Intermetallic structures forming in the interface have been characterized in detail. The Sn-coating layer completely melted and mixed with the liquid aluminum during the casting process. The reaction layer at the aluminum/steel interface is composed of ternary Al–Fe–Si particles and a thin layer of binary Al5Fe2 phase with thickness less than 1 µm. A small fraction of dispersed Sn-rich particles was observed distributing in the reaction layer and adjacent to eutectic Si particles in the A356 alloy. A sessile drop wetting test showed that Sn-coated steel substrates can be well wetted by aluminum melt. The improved wettability between A356 alloy melt and steel was attributed to the penetration and breaking of the aluminum oxide layer at the surface of the aluminum droplets by liquid Sn. Graphic Abstract

Effects of chromic acid anodizing on fatigue behavior of 7050 T7451 aluminum alloy

The effect of chromic acid anodizing (CAA) surface treatment on 7050 T7451 aluminum alloy was presented in this study in terms of fatigue behavior. CAA is a treatment against corrosion by producing aluminum oxide layer (Al2O3) at the surface. However, fatigue performance of 7050 T7451 is affected by the coating. In this study, eight different CAA processes were examined with regard to etching stage of pre-treatments by using an alkaline etchant and/or acid etchants with various immersion times. Optical microscopic examinations were applied in order to determine pitting characteristics for the selection of CAA process parameters before fatigue tests. A CAA process was selected among eight processes in terms of pitting characteristics in order to apply fatigue specimens. Four fatigue test groups were determined to investigate bare condition of 7050 T7451 and sub-stages of the CAA particularly. Constant amplitude axial fatigue tests were conducted on specimens at 91 Hz at stress ratio (R) -1 until run-out criteria, which was 106 cycles. Fatigue life reduction was determined due to pretreatments of CAA. Fracture surfaces of the specimens were examined by scanning electron microscope (SEM) to investigate morphology and crack initiation sites.

Synergy of Oxygen Plasma and Al2O3 Atomic Layer Deposition on Improved Electrochemical Stability of Activated Carbon-Based Supercapacitor

As a conventional electrode material of electric double-layer capacitors (EDLC), activated carbon (AC) still faces challenges to exhibit high capacitance. To address this problem, herein, we introduce a combined method of oxygen plasma and Al2O3 tomic layer deposition (ALD) on AC electrodes to reduce the impedance and improve the cycle stability of EDLC. The defect structure can be precisely designed by simply tuning the oxygen-plasma treatment time, thereby affecting the microstructures of AC electrode. Such a tactic permits the first-operated AC electrode with more defects and the ALD passivation of AC resulting in an outstanding rate performance for the device (40.6 F g–1 at 5 mA cm–2, 20.1 Fg–1 at 100 mA cm–2) and cycling stability (∼90% retention after 5,000 cycles). This benefit from the synergistic effect of defects from doped oxygen and stable aluminum oxide layer on the electrode surface. This work delivers a feasible strategy to construct a stable AC material with superior cycling performance for supercapacitor.

Enhanced Cementation of Co2+ and Ni2+ from Sulfate and Chloride Solutions Using Aluminum as an Electron Donor and Conductive Particles as an Electron Pathway

Cobalt and nickel have become important strategic resources because they are widely used for renewable energy technologies and rechargeable battery production. Cementation, an electrochemical deposition of noble metal ions using a less noble metal as an electron donor, is an important option to recover Co and Ni from dilute aqueous solutions of these metal ions. In this study, cementation experiments for recovering Co2+ and Ni2+ from sulfate and chloride solutions (pH = 4) were conducted at 298 K using Al powder as electron donor, and the effects of additives such as activated carbon (AC), TiO2, and SiO2 powders on the cementation efficiency were investigated. Without additives, cementation efficiencies of Co2+ and Ni2+ were almost zero in both sulfate and chloride solutions, mainly because of the presence of an aluminum oxide layer (Al2O3) on an Al surface, which inhibits electron transfer from Al to the metal ions. Addition of nonconductor (SiO2) did not affect the cementation efficiencies of Co2+ and Ni2+ using Al as electron donor, while addition of (semi)conductors such as AC or TiO2 enhanced the cementation efficiencies significantly. The results of surface analysis (Auger electron spectroscopy) for the cementation products when using TiO2/Al mixture showed that Co and Ni were deposited on TiO2 particles attached on the Al surface. This result suggests that conductors such as TiO2 act as an electron pathway from Al to Co2+ and Ni2+, even when an Al oxide layer covered on an Al surface.

Crystalline Silicon PERC Solar Cell with Ozonized AlOx Passivation Layer on the Rear Side

We present a method of ozonation to form the rear-side passivation layers of crystalline silicon PERC cells. In the method, a thin aluminum film was deposited on the back surface of a silicon wafer and then was oxidized into an aluminum oxide layer by gaseous ozone. Lifetimes of the wafers with such passivation layers proved to be increased with respect to those untreated, and the resultant PERC cells showed a performance improvement compared with standard cells with full back surface fields.