Encapsulation of aluminum flakes with hybrid silica/poly(acrylic acid) nanolayers by combination of sol–gel and in situ polymerization methods: a corrosion behavior study

A combination of sol–gel method and in situ polymerization was used to form a hybrid silica/poly(acrylic acid) nanolayer for the corrosion protection of aluminum pigments. To this end, the pigment particles were first coated with a silica layer by sol–gel method. Tetraethylorthosilicate was used as a precursor and during a condensation reaction, an inorganic silica layer was formed. Then, 3-methacryloxypropyltrimethoxysilane was attached on the surface and in situ polymerization of acrylic acid (AA), as a hydrophile monomer, was performed. The obtained Al/Si/PAA flakes were characterized by different methods such as Fourier transform infrared spectroscopy, energy-dispersive X-ray spectroscopy, scanning electron microscopy, and transmission electron microscopy (TEM). The attached PAA chains on the surface were deattached by HF aqueous solution and analyzed by gel permeation chromatography. Also, the surface energy of samples was measured using Owens and Wendt equation by means of contact angle data. As results, the characterizing tests approved the successful encapsulation of Al pigments and TEM image showed a 10–15 nm silica layer and a 20–25 nm PAA layer. Although the Al/Si pigments showed a quantity of evolved hydrogen, the hybrid coated pigments had excellent anticorrosive properties in acidic and alkaline solutions. Also, the surface free energy of Al/Si/PAA showed an increase compared to that of Al.