Beruflich Dokumente
Kultur Dokumente
225–234
www.elsevier.comrlocatersynmet
Abstract
Polypyrrole and polyŽ N-methylpyrrole. coatings have been successfully electrodeposited on steel substrates from aqueous oxalate
solutions. In acidic solutions, the electrodeposition process was characterized by three distinct stages. In this work the electrodeposition
process was first investigated by scanning electron microscopy ŽSEM., X-ray diffraction ŽXRD. and FTIR techniques. The adhesion and
corrosion performance of the electrodeposited coatings were then evaluated by single lap shear tests and tafel tests, respectively. Our
results reveal that deposition of FeC 2 O4 P 2H 2 O crystal layer first established the passivation of steel at the end of the first two stages, but
the formed FeC 2 O4 P 2H 2 O passive layer is subsequently decomposed followed by electropolymerization of pyrrole. Our results also
show that electrochemical process parameters had significant effects on the adhesion and corrosion performance of the electroposited
polypyrrole and polyŽ N-methylpyrrole. coatings. Polypyrrole coatings exhibited better adhesion and corrosion performance than
polyŽ N-methylpyrrole. coatings. q 2000 Published by Elsevier Science S.A.
2. Experimental The tafel test was conducted with a CMS 100 corrosion
measurement system, purchased from Gamry Instruments
2.1. Electrochemical synthesis ŽWillow Grove, PA.. A flat cell was used for the measure-
ments. The system consisted of a working electrode, a
Electrochemical reactions were performed in a one- platinum counter electrode and an SCE reference elec-
compartment polypropylene cell. The working electrode trode. The flat cell was filled with 1 M NaCl solution and
was a 0.5-mm-thick QD low-carbon steel panel provided was aerated with air during the test. A test spot with
by Q-panel. The counter electrodes comprised of two diameter of 1 cm was immersed into the solution during
titanium alloy plates. A saturated calomel electrode ŽSCE. the test.
was used as reference electrode. The working electrode
and the counter electrodes were used as anode and cath-
ode, respectively. Constant current method was the tech- 3. Results and discussion
nique used. The constant current source was supplied by
an EG & G Princeton Applied Research potentiostatr 3.1. Electrodeposition mechanism
galvanostat Model 273A.
The monomers used in this work were pyrrole and Fig. 1 shows the potential–time curves for the forma-
N-methylpyrrole. The initial concentrations of pyrrole and tion of polypyrrole coatings in different pH solutions at the
N-methylpyrrole were kept constant at 0.25 and 0.05 M, applied current density of 0.56 mArcm2 . In acidic solu-
respectively. The electrolyte used was a mixture of oxalic tions, the formation process of polypyrrole was character-
acid and certain amount of weak base Žpyrrole: ized by three distinct stages. The first two stages were
NaHCO 3 : N-methylpyrole:NŽC 2 H 5 . 3 .. The amount of weak related to the dissolution and passivation of steel. Our
base was adjusted so as to change the pH of the solutions previous results revealed that the dissolution and passiva-
from 1 to 10. Unless specified, the concentration of the tion of the steel was due to the deposition of a layer of
electrolyte was 0.1 M. All aqueous solutions used in the FeC 2 O4 P 2H 2 O crystals on the steel substrate and pH of
experiments were made from deionized water. the reaction solutions and applied current densities had
significant effect on the passivation time of the steel
w8,10,12,14x. As an example, Fig. 2 shows the formation
2.2. Characterization
process of the ironŽII. oxalate passive coating at pH s 1.4
and i s 0.56 mArcm2 .
The morphology of the samples was examined by scan- In this work, we further investigated the third stage of
ning electron microscopy ŽSEM. using a Hitachi S-4000 the reactions. It can be seen from Fig. 1 that the reaction
scanning electron microscope. Reflection–absorption in- potentials were not stable during the initial part of the
frared spectra ŽRAIR. of the samples were measured by a second stage for the acid solutions. In order to understand
BIO-RAD FTS-40 FTIR spectrometer. X-ray diffraction the reaction mechanism, a series of samples were prepared
ŽXRD. patterns of the electrodeposted coatings were stud-
ied by a Philips X’pert diffractometer with Cu K a radia-
tion. For RAIR and X-ray measurements, the samples used
were prepared by polished steel sheets.
Fig. 2. SEM micrographs of the samples formed at different time during the first stage, pH s 1.4, i s 0.56 mArcm2 .
at different times after the first two stages at pH s 1.4 and The obtained samples were first investigated by SEM.
i s 0.56 mArcm2 . For this part of investigation, the begin- Fig. 3 shows the SEM micrographs of the samples formed
ning of the third stage was regarded as zero reaction time. at different times after the first two stages. The formed
Fig. 3. SEM micrographs of the samples formed at different times during the second stage, pH s 1.4, i s 0.56 mArcm2 .
228 W. Su, J.O. Iroh r Synthetic Metals 114 (2000) 225–234
ironŽII. oxalate crystals still could be observed after 2.5 polypyrrole layer and detect the steel substrate. Therefore,
min reaction, but the size of the crystals became smaller above XRD results imply that ironŽII. oxalate coatings no
and the surface of the existing crystals became much longer existed on the steel surface after 3.5 min reaction.
rougher. It seems that some small crystals had already Fig. 5 shows the RAIR spectra of the samples formed at
disappeared. After 3.5 min reaction, no big crystals could different times after the first stage. The RAIR spectra of
be discerned on the steel substrate. It seems that most FeC 2 O4 P 2H 2 O and polypyrrole coatings have been dis-
crystals had gone after 3.5 min reaction. After 5 min cussed in our previous paper w12x. It can be seen that the
reaction, the morphology and color of the surface changed sample formed after 2.5 min reaction showed strong peaks
dramatically. It can be seen that the steel substrate was related to the ironŽII. oxalate coatings. No strong IR peaks
covered by black polypyrrole coating with fine micro- were observed for the sample formed after 3.5 min reac-
spheroidal grains. After 10 min reaction, the morphology tion. Because the substrate surface was not polished to
of polypyrrole coating can be seen more clearly and the mirror finish, very thin polypyrrole coating could not be
microspheroidal grains grew much larger. detected. However, for the sample formed after 10 min
The obtained samples were then investigated by XRD reaction, the strong IR peaks were observed and all the
technique. The results are shown in Fig. 4. For the sample peaks could be attributed to polypyrrole coatings.
formed after 2.5 min reaction, the diffraction peaks related Samples prepared at other conditions also showed simi-
to the ironŽII. oxalate were observed, but the peak intensi- lar phenomena. From the above discussion, it can be
ties were decreased compared to those of the passive concluded that the ironŽII. oxalate formed during the first
coating formed at the end of the first stage. When the stage actually decomposed again during the initial part of
reaction time was longer than 3.5 min, all samples ob- the second stage. Like any other ferrous compounds,
tained did not show any diffraction peaks related to the ironŽII. oxalate is also metastable. When the reaction
ironŽII. oxalate coatings. Because polypyrrole has a highly potential was raised to a higher value, the precipitated
disordered structure w15x, it does not show any diffraction ironŽII. oxalate would be further oxidized into highly
peaks. For all the samples, three strong diffraction peaks soluble ironŽIII. oxalate. Meanwhile, polypyrrole was de-
related to the steel substrate were observed when the XRD posited on the steel surface where ironŽII. oxalate was
was measured in the 2 u range of 408 to 908, indicating that decomposed so that the entire steel surface was still in
the disappearance of the diffraction peaks of FeC 2 O4 P passive state. Finally, polypyrrole would cover the entire
2H 2 O was not due to the penetration depth of X-ray. steel surface when ironŽII. oxalate was decomposed com-
Because the penetration depth of X-ray is usually a few pletely. Further electropolymerization of pyrrole would
microns w16x and the thickness of the formed polypyrrole occur on the polypyrrole surface rather than on ironŽII.
coatings was below 1.0 mm, X-ray could penetrate the oxalate surface.
Fig. 5. RAIR spectra of the samples formed at different times after the first stage, pH s 1.4, i s 0.56 mArcm2 .
Fig. 7 shows the adhesion strength of polypyrrole coat- in lower pH solutions. In fact, the polypyrrole coatings
ings formed in different conditions. For each pH solution, obtained at pH above 6.0 were actually very rough,
the adhesion strength of polypyrrole coatings decreased nonuniform, and very brittle. For example, the polypyrrole
slightly with increasing current densities. For the polypyr- coatings formed at pH s 6.0 and i s 3.38 mArcm2 had
role coatings formed at pH s 4.1, the adhesion strength adhesion strength of only about 2.4 MPa. Because the
became very close for the two applied current densities. It epoxy used was almost transparent and the steel substrates
can be seen from Fig. 7 that pH of the solutions had and the polypyrrole coatings showed white and black
significant effect on the adhesion strength of polypyrrole color, respectively, the failure mode could be seen visu-
coatings. When the pH of the solutions was below 4.1, all ally. For the control sample, failure occurred at the adhe-
the polypyrrole coatings exhibited higher adhesion strength sive–steel interface. All the epoxy adhesive was attached
than the control sample, but the adhesion strength de- to only one side of the failure surface. The failure mode of
creased slightly with pH for each applied current density. the polypyrrole coatings was changed with pH of the
For example, the polypyrrole coating formed at pH 2.4 and solutions. For all the polypyrrole coatings formed at pH
1.13 mArcm2 had adhesion strength about 20.2 MPa, below 4.1, failure occurred cohesively within polypyrrole.
which was about 5.5 MPa higher than that of the epoxy It could be seen very clearly that both sides of the failure
adhesive. The polypyrrole coatings formed at pH above surfaces were covered by black polypyrrole. For the
6.0 demonstrated much lower adhesion strength compared polypyrrole coatings formed at pH above 6.0, failure events
to the control sample and the polypyrrole coatings formed were observed at the polypyrrole–steel interface. It was
230 W. Su, J.O. Iroh r Synthetic Metals 114 (2000) 225–234
Fig. 7. Adhesion strength of steel coated with polypyrrole as a function of Fig. 9. Adhesion strength of steel coated with polyŽ N-methylpyrrole. as a
pH and applied current. function of oxalic acid concentration.
W. Su, J.O. Iroh r Synthetic Metals 114 (2000) 225–234 231
increasing pH. Fig. 9 also compares the adhesion strength methylpyrrole. in all solvents, it is very hard to character-
of the polyŽ N-methylpyrrole. coatings formed at different ize their molecular weight and their structure. However,
electrolyte concentration. It can be seen that the adhesion because the electropolymerization reactions occurred
strength of polyŽ N-methylpyrrole. coatings decreased through the radical cation intermediates w18,19x, it is quite
slightly with increasing electrolyte concentration. For all possible that higher pH and applied current densities could
the polyŽ N-methylpyrrole. coatings, failure events oc- lead to shorter chain length and lower mechanical proper-
curred between coating–steel interface. It was found that ties.
black polyŽ N-methylpyrrole. coatings were all attached to
the adhesive side.
3.3. Corrosion performance
In order to further understand the adhesion mechanism,
a series of pyrrole and N-methylpyrrole copolymers were
also prepared by electrochemical method. It has been Tafel test is a DC corrosion test to determine the
reported that the composition of the pyrrole and N-methyl- corrosion current Icorr and corrosion potential Ecorr of
pyrrole copolymers is similar to their feed ratio w17x, thus metals. From tafel measurements, the corrosion rate can be
monomer feed ratio can be used to represent the composi- calculated according to following equation w20x:
tion of the copolymers. Fig. 10 shows the relationship CR Ž mmryearr. s 3272 Icorr Ž EW . r Ž Ad . Ž 1.
between the adhesion strength and the composition of the
copolymers. It can be seen that the adhesion strength of the where CR is the corrosion rate in millimeters per year, Icorr
copolymers increased with increasing pyrrole content. The is the corrosion current in amperes per square centimeter,
failure mode of the lap joints was also influenced by the EW is the equivalent weight of the oxidized element in
composition of the copolymers. It changed gradually from gramsrequivalent, A is the surface area of the specimen in
interfacial failure to cohesive failure with increasing pyr- square centimeters, and d is the density of the specimen in
role content. For the copolymer containing 80 mol% of grams per cubic sentimeter.
pyrrole, the failure mode was very similar to that of the All the samples used for tafel tests were prepared at the
pure polypyrrole. applied current density of 1.13 mArcm2 . All polypyrrole
From the above discussion, it seems that –NH groups coatings had a thickness of about 2.0 mm while the
of the polypyrrole chains play an important role for the polyŽ N-methylpyrrole. coatings formed at pH s 1.4 and
higher adhesion strength of polypyrrole coatings. Perhaps 2.7 had thickness of about 1.5 and 1.0 mm, respectively.
–NH groups could form some kind of chemical bonding As an example, Fig. 11 shows the obtained Tafel curves
with the steel substrate. The influence of pH and applied for the bare steel, polypyrrole and polyŽ N-methylpyrrole.
current densities on the adhesion of polypyrrole and coatings. The polypyrrole and polyŽ N-methylpyrrole. coat-
polyŽ N-methylpyrrole. coatings is not very clear so far. ings were all prepared at pH s 1.4 and i s 1.13 mArcm2 .
Because of the insolubility of polypyrrole and polyŽ N- Table 1 lists the obtained tafel results for all the samples. It
can be seen that electrodeposited ironŽII. oxalate coatings
had a lower corrosion potentials and higher corrosion
currents and corrosion rates than the bare steel, indicating
that they were not corrosion inhibitor for steel. However, it
can be seen from Table 1 that polypyrrole coatings greatly
raised the corrosion potential Ecorr and reduced the corro-
sion current Icorr . The corrosion rate of steel was also
significantly reduced as result of the reduction of Icorr .
These results indicate that polypyrrole coatings could act
as a protection layer on steel substrate and improve the
overall corrosion performance. The corrosion performance
of polypyrrole coatings was also influenced by pH of the
solutions. For all the polypyrrole coatings, the polypyrrole
coating formed at pH s 2.4 showed the best corrosion
performance. Compared to polypyrrole, polyŽ N-methylpyr-
role. coatings only slightly improved the corrosion poten-
tial Ecorr . Although polyŽ N-methylpyrrole. coatings also
reduced the corrosion current and corrosion rate of steel,
some defects were found on the coatings after the mea-
sured coatings were erased with soft paper. PolyŽ N-meth-
Fig. 10. Dependence of the adhesion strength of steel coated with
ylpyrrole. coatings had relatively low adhesion strength to
polypyrrole-co-polyŽ N-methylpyrrole. as a function of mole % of pyrrole the steel substrates. Due to the irregularity of its structure,
in the feed. polyŽ N-methylpyrrole. might have high permeability for
232 W. Su, J.O. Iroh r Synthetic Metals 114 (2000) 225–234
Fig. 11. DC polarization curves for uncoated low carbon steel, polypyrrole coated low carbon steel and polyŽ N-methylpyrrole. coated steel.
W. Su, J.O. Iroh r Synthetic Metals 114 (2000) 225–234 233
4. Conclusions
water, resulting in the loss of adhesion at some part of the
coatings.
From above discussion, it can be seen that polypyrrole The results presented in this study revealed a very
also shows better corrosion performance than polyŽ N- interesting mechanism for the electrodeposition of polypyr-
methylpyrrole.. Polypyrrole is a conjugated system, having role coatings on steel substrates from aqueous oxalate
alternative single and double bonds, furthermore, it also solutions, that is, FeC 2 O4 P 2H 2 O coating was first de-
carries polar –NH and oxalate groups. The polypyrrole posited on the steel substrate and passivated the steel
Fig. 12. Schematic representation of the anodic inhibiting function of polypyrrole coatings formed on steel: anode 1; uncoated steel, anode 2; steel coated
with PPy, Ecorr1 and Ecorr2 , corrosion potentials for uncoated steel and PPy coated steel, respectively, Icorr1 and Icorr2 , corrosion currents for uncoated steel
and steel coated with PPy.
234 W. Su, J.O. Iroh r Synthetic Metals 114 (2000) 225–234