Zeolite Y coatings on Al-2024-T3 substrate by a three-step synthesis method

A zeolite Y coating has been formed on aluminum alloy 2024-T3 (Al 2024-T3) by a novel three-step synthesis method. In the first step, the bottom layer is formed by synthesizing a high-silica-zeolite (HSZ) ZSM-5 film on the Al 2024-T3 substrate. In the second step, the ZSM-5 film is seeded with zeolite Y followed by a short ZSM-5 synthesis to form the bridging layer. Finally, the low-silica-zeolite (LSZ) Y film is synthesized on the bridging layer by seeded growth to form the top layer. The ZSM-5 film offers excellent corrosion protection for the aluminum under the high pH conditions required for LSZ Y synthesis. The bridging layer is critical in providing adhesion between the bottom and top layers.