A multilayer coating with optimized properties for corrosion protection of Al

In the context of a universal search for alternatives to chromate-based coatings, which are toxic for both human beings and the environment, a multilayer coating for Al protection purposes is developed and investigated in the current work. The first layer is selected to be a hexamethyldisiloxane-based plasma polymer film (PPF), deposited by Plasma Enhanced Chemical Vapor Deposition (PECVD), due to a number of interesting features that are characteristic of plasma polymers. The second layer is synthesized via the polymerization of the 2-ethylhexyl acrylate monomer initiated from the free radicals trapped on the surface of the PPF during its growth. A subsequent layer of a copolymer of 2-ethylhexyl acrylate and glycidyl methacrylate, poly(EHA-co-GMA), is deposited by spin coating to increase the corrosion resistance of the coating. An improvement in the anti-corrosion properties of the multilayer coating by approximately three orders of magnitude as compared to the uncoated Al substrate is observed. Further enhancement of the adhesion and scratch resistance properties is addressed via UV-crosslinking and the incorporation of in situ generated silica nanoparticles into the final layer.