Organic-inorganic hybrid films, ormosils, have been investigated as corrosion resistant coatings for 2024-T3 aluminum alloys. These films were found to provide good corrosion protection, good compatibility with organic primers, and excellent filiform corrosion resistance as evaluated using
accelerated 168 hour salt spray, 2000 hour salt spray, and filiform corrosion tests. Composite coatings composed of AA surface pretreatment with either trivalent chromium or alodine conversion coatings followed by the deposition of an ormosil film were prepared. Such composite coatings resisted corrosion in a manner superior to bare aluminum or a single layer ormosil coating. The impact of the
Cr(III)-based conversion coating on corrosion resistance of the composite fihns is comparable to that of the Cr(VI)-based alodine surface pretreatment. This implies that the environmentally compliant and
non-toxic trivalent chromium conversion coating is a potential alternative for the hazardous and carcinogenic alodine treatment.
Keywords: sol-gel, corrosion resistance, salt spray, filiform, conversion coatings, ormosil