Growth of MFI zeolite film as corrosion protection layer of aluminum alloy

• Synergism between zeolite film and interfacial layer preventing from NaCl attack.
• Strong anti-corrosion property induced by dense zeolite films and strong interfacial layers.
• DGC grows dense zeolite film for enhanced anti-corrosion capability.
• H2O2 pre-treatment provides stronger interfacial layers than NaOH pre-treatment.
• Electrochemical impedance spectroscopy for characterization of anti-corrosion film.

The dry-gel-conversion (DGC) and the in-situ crystallization (InC) for the growth of MFI zeolite films were examined. The combination of DGC method and H2O2 pre-treatment showed the best corrosion protection performance. The corrosion rate was reduced by five orders of magnitude in reference to the bare-substrate in NaCl solutions. Based on the electrochemical spectroscopy, the anti-corrosion property could be attributed to the formation of dense zeolite films and strongly bonded interfacial layers that acting as barrier layers for the protection against corrosive species. The corrosion resistances of the interfacial layer could be upgraded by either the InC or DGC grown MFI zeolite film.

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