article · Scientific Reports
Protective nano-alumina coatings were applied to titanium dioxide ceramic substrates using microwave combustion and polymeric methods to improve their resistance to corrosion. Substrates prepared by firing at 1000 degrees Celsius achieved optimal physical properties, exhibiting both rutile and anatase phases. Applying the coating and heating at 1000 degrees Celsius transformed the remaining anatase phase into rutile. Across the tests, the addition of the nano-alumina layer decreased porosity and raised the compressive strength of the ceramics. Testing in a corrosive 0.5 M sulphuric acid solution revealed that the coating reduced the corrosion rate from 67.71 to 16.30 millimetres per year, achieving an inhibition efficiency of up to 78.56 percent. Overall, the substrate coated via the polymeric method and calcined at 800 degrees Celsius delivered the best combination of physical, mechanical, and corrosion-resistant performance.
Ceramic materials exposed to harsh, acidic environments frequently suffer from chemical degradation and mechanical wear. By applying a protective nano-alumina layer using relatively simple processing techniques, the durability and strength of titanium dioxide ceramics can be significantly enhanced. This approach offers a clear method to reduce acid-induced corrosion and prolong the operational lifespan of high-strength ceramic parts.
This work is early-stage research focused on laboratory-scale coating formulation and corrosion testing. The approach could eventually serve industrial sectors requiring acid-resistant structural ceramics, such as chemical processing and materials handling operations. However, the abstract outlines laboratory characterisation rather than scalable manufacturing, indicating that significant further testing and process development are required before practical deployment.
AI-generated from the published abstract. Always read the original work before citing.
Abstract The study describes the successful development of a TiO 2 ceramic substrate with a protective nano-Al 2 O 3 coating using two different coating techniques: microwave combustion and polymeric methods. The coated ceramics demonstrate enhanced corrosion resistance compared to the uncoated substrate. The optimal TiO 2 substrate was prepared by firing it at 1000 °C. This was done to give the desired physical properties of the TiO 2 substrate for the coating procedures. Nano-Al 2 O 3 powder was coated onto the surface of the TiO 2 substrates. The TiO 2 substrates with the Al 2 O 3 coating were then calcined (heat-treated) at 800 and 1000 °C. The structures, morphology, phase composition, apparent porosity, bulk density, and compressive strength of the substrate and coated substrate were characterized. Upon firing at 1000 °C, it was discovered that the two phases of TiO 2 —rutile and anatase—combine in the substrate. Once the substrate has been coated with nano Al 2 O 3 at 1000 °C, the anatase is transferred into rutile. When compared to the substrate, the coated substrate resulted in a decrease in porosity and an increase in strength. The efficiency of the ceramic metal nanoparticles Al 2 O 3 as a good coating material to protect the TiO 2 substrates against the effect of the corrosive medium 0.5 M solution of H 2 SO 4 was measured by two methods: potentio-dynamic polarization (PDP) and the electrochemical impedance spectroscopy (EIS). The results indicated that the corrosion rate was decreased after the substrate coated with alumina from (67.71 to 16.30 C.R. mm/year) and the percentage of the inhibition efficiency recorded a high value reaching (78.56%). The surface morphology and composition after electrochemical measurements are investigated using SEM and EDX analysis. After conducting the corrosion tests and all the characterization, the results indicated that the coated TiO 2 substrate prepared by the polymeric method at 800 °C displayed the best physical, mechanical, and corrosion-resistant behavior.
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DOI: 10.1038/s41598-024-68566-6
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