B16
Journal of The Electrochemical Society, 150 ͑1͒ B16-B25 ͑2003͒
0
013-4651/2002/150͑1͒/B16/10/$7.00 © The Electrochemical Society, Inc.
Chromate Conversion Coatings Formation on Zinc Studied
by Electrochemical and Electrohydrodynamical Impedances
a,b
b,
a, ,z
a,c
A. A. O. Magalh
and O. E. Barcia
˜
aes, B. Tribollet, * O. R. Mattos, * I. C. P. Margarit,
d
aPrograma de Engenharia Metalurgica e de Materials/Dipartamento de Engenharia Metal u´ rgica e de
Materials/Instituto Alberto Luiz Coimbra de P o` s Gradua c¸ ao e Pequ `ı sa de Engenharia, Escola de Engenharia
˜
Universidade Federal do Rio de Janeiro, Rio de Janeiro, Brazil
b
Unit e´ Propre de Recherche 15 du Centre National de la Recherche Scientifique/Physique des Liquides et
Electrochimie, Universit e´ Paris VI, Paris, France
c
Escola de Qu ´ı mica Departamento de Processos Inorg aˆ nicos, dInstituto de Qu ´ı mica, Departamento de
Fis ´ı co-Qu ´ı mica, Universidade Federal do Rio de Janeiro, Rio de Janeiro, Brazil
The formation of chromate conversion coatings on zinc was studied by chronopotentiometric, electrochemical, and electrohydro-
dynamic impedances, and interfacial pH measurements. The electrochemical experiments were performed with a rotating disk
electrode of pure zinc, and the pH measurements were obtained with a zinc deposit on a gold grid electrode in a submerged
impinging jet cell. The electrolyte was an industrial chromate bath. The experimental results were achieved for different immer-
sion times, temperatures, and rotation speeds. Kinetic reactions and physical model for the chromate layer formation on zinc were
proposed, and the electrochemical and electrohydrodynamic impedances were well simulated.
©
2002 The Electrochemical Society. ͓DOI: 10.1149/1.1528196͔ All rights reserved.
Manuscript submitted January 18, 2002; revised manuscript received July 22, 2002. Available electronically December 13, 2002.
Several sectors of automobile, aerospace, and electrical appli-
the two main stages for the formation of a layers of chromatation are
the dissolution of zinc in an acidic electrolyte and the formation of a
precipitate of trivalent chromium.
ances industries improve the anticorrosive properties of their galva-
nized products by application of chromate conversion coatings on
zinc deposits. The objective is to decrease the formation of corrosion
products, and, thereby, to avoid modification of their properties dur-
ing transportation and storage. The conversion treatments can also
act as a support for the application of painting if direct adherence of
the organic coatings on the substrate is not satisfactory. The prin-
ciple of a conversion treatment consists basically in transforming the
surface of the metallic substrate from the active state to the passive
state. The formed layer is composed of a combination of reduced
species products from ions present in the conversion bath and, in
smaller quantities, corrosion products from the substrate.
Trivalent chromium can form different types of oxides and/or
hydroxide compounds. During reduction of hexavalent chromium
ϩ
there is a consumption of H , which increases the local pH and
allows precipitation of a gel-like film.
The aim of this work is to employ infrequently used modern
electrochemical techniques in the chromatation process studies. We
hope that this approach can be useful for further research concerning
nontoxic alternatives for conversion baths.
Experimental
The chromate coating is usually applied on galvanized steels
through simple immersion in an acidic solution that contains chro-
mium hexavalent species. The quality and the efficiency of these
layers are strongly dependent on the bath composition, the surface
of substrate, and the parameters of the process. Many studies in the
literature concern the mechanisms of deterioration and the develop-
ment of control and assessment methods for the quality of these
All the electrochemical measurements were performed with a
three-electrode cell. The working electrode was manufactured from
pure zinc ͑99.9%͒ rod. This electrode was covered by a cataphoretic
2
paint and coated with a resin epoxy to expose a 0.27 cm cross-
sectional area to the electrolyte. The electrode surface treatment pro-
tocol consisted of polishing with emery paper 600 and 1200, rinsing
with double-distilled water, rinsing with ethanol, and finally drying
with air. The reference electrode was a saturated calomel electrode
1
-8
conversion layers. Even though chromatation is used in industry
its deposition mechanism is not yet completely understood.
͑SCE͒ and the counter electrode was a large platinum grid.
The chemical composition of these layers is not yet well defined;
the difficulties of a composition survey of this type are due mainly
to the thinness of the layers. The main parameters that control the
composition of the chromatation layers on zinc are the quality of the
zinc surface, the composition of the bath, the pH of the solution, the
immersion time in the bath, the bath temperature, and the thickness
of the layer. According to the majority of works, the main constitu-
ent of the formed layer is trivalent chromium in the form of
The electrolytic solution was a 5% v/v solution of a concentrated
commercial product, which consisted primarily of sodium chromate
and sulfuric acid. This solution is used in the chromatation step of an
electrogalvanized steel industrial process in a Brazilian metallurgy
society. The chromate conversion coatings formed by this solution
with temperature between 47 and 48°C and pH between 2.96 and
.00, showed good corrosion resistance as presented previously.1
3
The electrochemical tests were conducted at pH 3.0, at tempera-
tures of 25 and 47°C, controlled by a thermostatic bath.
9
-12
4,7,13
3,14,15
oxides,
hydroxides,
and complex.
The hexavalent chro-
mium species is found in least quantity in the form of complex
compounds with trivalent chromium or simply absorbed in the layer.
Only trace amounts of zinc and such activator anions as phosphates,
nitrates, sulfates, chlorides, and fluorides are present.
Although there are a great variety and complexity of reactions
proposed for the zinc/chromate solution interface,16 this formation
obeys a zero net current as a result of the compensation of a reduc-
tion component from the electrolyte and an oxidization component
of the metal. A consensus exists in the literature that maintains that
The zinc rotating disk electrode ͑RDE͒ open-circuit potential
͑OCP͒ evolution in the chromate solution was achieved using a po-
tentiostat Ominimetra model PG-19 for 30 min of immersion for
four different rotation speeds ͑0, 250, 500, and 1000 rpm͒. A dc
motor with a servo system controlled the RDE and the rotation rate
was measured with a tachometer made by Asservissement Eletron-
ique under a CNRS/France license. The ac impedance measurements
were conducted at the OCP of the system under potentiostatic regu-
lation at three different immersion times: 2, 15, and 30 min, and
three rotation speeds: 250, 500, and 1000 rpm. The electrohydrody-
namic impedance spectroscopy ͑EHD͒ measurements were con-
ducted under potentiostatic regulation. The rotation rate was initially
fixed at 1000 rpm, and after 15 and 30 min of immersion, the OCP
*
Electrochemical Society Active Member.
E-mail: Omattos@metalmat.ufrj.br
z