Comparative performance of Cathodic Electrodeposition, powder, and zinc flake organic coatings on Nano‑Treated AA1050, AA5005, and AA7075 Aluminum Alloys

Abstract

This study presents a comparative assessment of organic coating systems applied to nano-treated 1050, 5005, and 7075 aluminum alloys, aiming to enhance corrosion resistance in high-performance industrial environments. The alloys were subjected to a zirconium oxide-based nano pretreatment with varying activation durations (60–90 s) and coating times (6–8 min). Subsequently, three distinct organic coating methods were applied: cathodic electrodeposition (CED), powder coating, and zinc flake coating. The performance of the coatings was evaluated using cross-cut adhesion tests, cyclic corrosion tests (EN ISO 11997-1 Cycle B, Renault 47-01-000-E), and copper-accelerated acetic acid salt spray (CASS) tests (DIN 50 021). Coating thicknesses were determined via scanning electron microscopy (SEM). The findings revealed that zinc flake coatings failed the adhesion tests, whereas CED and powder coatings demonstrated high performance under optimized pretreatment conditions (90 s activation, 8 min nano coating). Notably, the 7075-alloy exhibited superior compatibility across multiple tests, achieving the highest corrosion resistance with CED coatings. These results offer a practical roadmap for selecting environmentally friendly and high-performance coating strategies for aluminum alloys intended for use in harsh service conditions

Keywords

• Aluminum alloys
• Nano-coating
• Cathodic
• electrodeposition
• Powder coating
• Corrosion resistance

Nano-Yüzey işlemi uygulanmış AA1050, AA5005 ve AA7075 Alüminyum alaşımları üzerine uygulanan Katodik Elektroforetik, toz ve çinko pul organik kaplamaların karşılaştırmalı performansı

Abstract

Bu çalışma, yüksek performanslı endüstriyel ortamlarda korozyon direncini artırmayı amaçlayan nano-işlem görmüş 1050, 5005 ve 7075 alüminyum alaşımlarına uygulanan organik kaplama sistemlerinin karşılaştırmalı bir değerlendirmesini sunmaktadır. Alaşımlar, değişken aktivasyon süreleri (60–90 sn) ve kaplama süreleri (6–8 dk) ile zirkonyum oksit bazlı bir nano ön işlem sürecine tabi tutulmuştur. Ardından üç farklı organik kaplama yöntemi uygulanmıştır: katodik elektro biriktirme (CED), toz kaplama ve çinko lamel kaplama. Kaplamaların performansı; cross-cut yapışma testleri, çevrimsel korozyon testleri (EN ISO 11997-1 Döngü B, Renault 47-01-000-E) ve bakır hızlandırmalı asetik asitli tuz püskürtme (CASS) testleri (DIN 50 021) ile değerlendirilmiştir. Kaplama kalınlıkları taramalı elektron mikroskobu (SEM) ile belirlenmiştir. Elde edilen bulgular, çinko lamelli kaplamaların yapışma testlerinde başarısız olduğunu; buna karşılık CED ve toz kaplamaların optimize edilmiş ön işlem koşullarında (90 sn aktivasyon, 8 dk nano kaplama) yüksek performans sergilediğini ortaya koymuştur. Özellikle 7075 alaşımı, çoklu testlerde üstün uyumluluk göstermiş ve CED kaplamalarla en yüksek korozyon direncine ulaşmıştır. Bu sonuçlar, zorlu hizmet koşullarında kullanılacak alüminyum alaşımlar için çevre dostu ve yüksek performanslı kaplama stratejilerinin seçimine yönelik pratik bir yol haritası sunmaktadır.

Keywords

• Alüminyum alaşımları
• Nano kaplama
• Kataforez kaplama
• Toz kaplama
• Korozyon direnci

References

1. [1] Zhou B, Liu B, and Zhang S. “The advancement of 7XXX series aluminum alloys for aircraft structures: a review”. Metals, 11(5), 718, 2021.
2. [2] Sun Y. “The use of aluminum alloys in structures: review and outlook,” Structures, 57, 105290-105298, 2023.
3. [3] Joseph R, Davis JR. “Aluminum and Aluminum Alloys”. Ilustrated ed. Ohio, USA, ASM international, 1993.
4. [4] Ezuber H, El-Houd A, El-Shawesh F. “A study on the corrosion behavior of aluminum alloys in seawater,” Materials & Design, 29(4), 801–805, 2008.
5. [5] Feng Z, Li J, Ma J, Su Y, Zheng X, Mao Y, Zhao Z. “EBSD characterization of 7075 aluminum alloy and its corrosion behaviors in SRB marine environment”. Journal of Marine Science and Engineering, 10(6), 740, 2022.
6. [6] Liu L, Li Y, Wang F. “Electrochemical corrosion behavior of nanocrystalline materials-a review”. Journal of Materials Science & Technology, 26(1), 1-14, 2010.
7. [7] Udhayakumar M, Radhika N, Arun KL. “A comprehensive review on nanocrystalline coatings: properties, challenges and applications”. Journal of Bio- and Tribo-Corrosion, 8, 83, 2022.
8. [8] Shri Prakash B, Balaraju J N. "Chromate (Cr6+)-free surface treatments for active corrosion protection of aluminum alloys: a review." Journal of Coatings Technology and Research, 21(1), 105-135, 2024.

9. [9] Yange Y, Jingyi C, Xingqi W, Zhigang F, Hongfei Y, Baoxing Y, Fuhui W. “Design and performance of Zr-and/or Ti-based chemical conversion coatings for light alloys”. Journal of Chinese Society for Corrosion and Protection, 42(3), 387-394, 2021.
10. [10] Oki M, Charles E, Ikubanni PP. “Corrosion and adhesion performance of ferric ion-based hybrid nano-conversion coatings on aluminum alloy”. Cureus Journal of Engineerings, 2, es44388-025-07832-3, 2025.
11. [11] Tamurejo-Alonso P, González-Martín ML, Pacha-Olivenza MA. “Electrodeposited zinc coatings for biomedical application: morphology, corrosion and biological behaviour”. Materials, 16(17), 5985, 2023.
12. [12] Marcus P. Corrosion Mechanisms in Theory and Practice. 2nd ed. New York, USA, Marcel Dekker, 2002.
13. [13] Feldmann F, Mears LLE, Roth M, Valtiner M. “Characterisation of the galvanic protection of zinc flake coating by spectroelectrochemistry and industrial testing”. Materials and Corrosion, 74(8), 1148–1158, 2023.
14. [14] Oleksiak B, Kołtało K, Poloczek R. “Application methods and selected properties of zinc flake coatings”. Metalurgija, 60(1-2), 162–164, 2021.
15. [15] Matei A, Tutunaru O, Tucureanu V. “Surface pre-treatment of aluminum alloys for the deposition of composite materials”. Materials Science and Engineering: B-Advanced Functional Solid-state Materials, 263, 114874, 2021.
16. [16] Carreira AF, Pereira AM, Vaz EP, Cabral AM, Ghidini T, Pigliaru L, Rohr T. “Alternative corrosion protection pretreatments for aluminum alloys”. Journal of Coatings Technology and Research, 14(4), 879-892, 2017.
17. [17] Kılınç M. Kataforez kaplama üzerine solvent bazlı ve su bazlı lamelli kaplama uygulamaları ile oluşacak dubleks kaplamanın korozyon ve ömür testine etkisinin incelenmesi. Yüksek Lisans Tezi, Eskişehir Teknik Üniversitesi, Eskişehir, Türkiye, 2019.
18. [18] Polat DB, Timur İS, Keleş Ö. “Çinko-alüminyum alaşımından üretilmiş döküm parçalarının korozyon direncine bakır kaplama proseslerinin etkisi”.Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji, 1(3), 103–113, 2013.
19. [19] Eren B. Döküm Malzemelerin Performans Dayanımını Artırmaya Yönelik Kaplama Araştırması. Yüksek Lisans Tezi, Bilecik Şeyh Edebali Üniversitesi, Bilecik, Türkiye, 2020.
20. [20] Özçanak T. Kataforez Kaplama Öncesinde Yüzey Hazırlama, Kurutma ve Kaplama Proseslerinin Incelenmesi. Yüksek Lisans Tezi, Yıldız Teknik Üniversitesi, İstanbul, Türkiye, 2008.
21. [21] Chenoll-Mora E, Cloquell-Ballester VA. “Review and long-term corrosion analysis of coatings based on Zinc-Aluminium-Magnesium alloys, as an alternative to traditional zinc-based coatings for cable trunking systems in electrical installations”. Novasinergia, 2(1), 50–79, 2019.
22. [22] Özden F. Elektrostatik Toz Boya Proses Parametrelerinin Deney Tasarımı ile Optimizasyonu ve Endüstriyel Uygulaması. Yüksek Lisans Tezi, Balıkesir Üniversitesi, Balıkesir, Türkiye, 2020.
23. [23] Zhao X, Qi Y, Zhang Z, Li K. “The influence of glass flake and micaceous iron oxide on electrochemical corrosion performance of waterborne silicate coatings in 3.5% NaCl solution”. Coatings, 9(12), 833, 2019.
24. [24] Barua S, Rahman MA, Chandra Bhowmik K, Khan I. “Corrosion resistance of anodized and composite‐coated aluminum alloys: A Comprehensive Review on 5xxx and 6xxx Series”. Advances in Materials Science and Engineering, 2025(1), 7941108, 2025.
25. [25] Cui C, Mu, X, Sun Z, Xiao K. “Correlation between the accelerated-rate decay mechanism in neutral salt spray tests and the atmospheric corrosion kinetics model of a 7075 aluminum alloy in Marine Environments”. Metals, 16(1), 45, 2025.
26. [26] Cornet AJ, Homborg AM, ‘t Hoen-Velterop L, Mol JMC. “Degradation of structural aircraft coatings in cyclic salt spray testing, outdoor exposure, and in-service environments.” Journal of Coatings Technology and Research, 23(3), 1431-1460, 2026.
27. [27] Minaz C. 1050, 5005, 7075 Alüminyum Tipi Malzemelerin Üzerine Uygulanan Nano Yüzey Işlem Sonrasında Yapılan Organik Kaplamaların Korozyon Davranışının Incelenmesi. Yüksek Lisans Tezi, Bilecik Şeyh Edebali Üniversitesi, Bilecik, Türkiye, 2022.
28. [28] Hu HS, Zhao TY, Li H, Sun HJ, Wu L K, Cao FH. “A novel organic-reinforced zirconium-based composite conversion coating with long-term corrosion resistance property for ADC12 aluminum alloy”. Surfaces and Interfaces, 62, 106301, 2025.
29. [29] Fan J, Luo S, Zheng L, Song Z, Pen X. “Fabrication of vanadium–zirconium conversion coatings on 6061 aluminum alloy and performance modulation by additives”. Coatings, 15(12), 1382, 2025.
30. [30] Sen S, Chatterjee A, Ramakanth D, Singh S, Maji PK. “Recent advances in cathodic electrodeposition coatings with special reference to resin materials: A comprehensive review”. Progress in Organic Coatings, 190, 108387, 2024.
31. [31] Hussain AK, Seetharamaiah N, Pichumani M, Chakra CS. “Research progress in organic zinc rich primer coatings for cathodic protection of metals–A comprehensive review”. Progress in Organic Coatings, 153, 106040, 2021.