Aluminium electroplated from ionic liquids as protective coating against steel corrosion

The protective action of thin layers of aluminium electroplated on a carbon steel (UNI Fe360B) has been studied. The coatings were obtained via electroreduction, at room temperature, from an ionic liquid constituted by 1-butyl-3-methyl-imidazolium heptachloroaluminate. Coatings of different thickness, ranging from 10 to 40 μm, were obtained. Their morphology and chemical composition were investigated using SEM microscopy coupled with EDX microanalysis and X-ray diffraction. Electrochemical tests (potentiodynamic polarization curves, open-circuit potential and electrochemical impedance spectroscopy) were performed in order to characterise the corrosion resistance of the coating in 3.5% NaCl aqueous solution. Visual investigation of the samples during long term of exposition to neutral salt spray gave an evaluation of their free corrosion properties. It was found that the aluminium layers deposited from ionic liquids significantly protect the substrate from the general corrosion and this action increases with the coating thickness.