Key steps influencing the formation of ZSM-5 films on aluminum substrates

Zeolite ZSM-5 films were synthesized on various supports, including aluminum alloys widely used in aerospace industry. The different key steps influencing the formation of the MFI films, from substrates cleaning to in situ crystallization time were investigated. A complete characterization of the hybrid material is proposed using various techniques, such as X-ray diffraction, scanning electron microscopy, X-ray fluorescence, scratch test and nitrogen/n-hexane sorption measurements. A minimum 9 μm thick, dense, continuous and highly crystallized film of ZSM-5 zeolite has been obtained. Depending on the substrate nature, the ZSM-5 film molar Si/Al ratio can vary between 15 and 30. The microporous coating is well adhered to the aluminum substrates. Sorption capacities were identical on ZSM-5 films compared to corresponding powders, revealing the absence of additional diffusion barriers. The mechanical stability and sorption capacity of the ZSM-5 films are promising for technological uses in space decontamination and corrosion protection of aluminum substrates.

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► Well-crystallized zeolite ZSM-5 films on different aluminum substrates.
► The optimization of various synthesis key parameters.
► The good adhesion of the zeolite films on the substrates.
► Good sorption capacities of the ZSM-5 films.