Elimination of a zero-growth in thickness of Al₂O₃ protective film deposited by cycles of dip-coating method

Multilayered alumina film was deposited onto metallic substrate using cycles of dip-coating method. The film thickness was found not always growing linearly with the increase of the number of dipping cycles, and even a zero-growth in thickness was observed after 20 cycles of dip coatings. This phenomenon was found to be attributed to the dissolving behavior of alumina gel material in original sol. A heat treatment at a temperature higher than 230 °C was found to be able to effectively lower the dissolvability of Al₂O₃ gel material, but an extra high temperature, i.e., 600 °C led to the formation of cracks in the multilayered film due to the increase of interfacial tension force. It was examined by IR and XRD analyses that a heat treatment at 250 °C for 10 min before each coating process could yield an amorphous multilayered film with no crack formed after calcinations at 600 °C. A crack-free Al₂O₃ film with a thickness up to 2 μm after 22 cycles of dip coating process could be produced and it showed an excellent antioxidation performance for steel substrate.