In this work a diffusion-driven inhibitor transport model is used to help in the design of inhibitor-loaded carriers for anticorrosive primers. The work focuses on inhibitor release at damaged locations of different dimensions exposed to electrolyte and is validated experimentally. The damage dimensions are first simulated to determine the minimal inhibitor release rate necessary to reach the required inhibitor concentrations for corrosion protection of the exposed metal. Kinematic and mass conservation laws are then used as first-order approximations to study the effect of different characteristics of nano- and micro-particles loaded with inhibitors embedded in an organic coating during the first 100 s of immersion. The simulated results are validated experimentally using epoxy coatings containing cerium-loaded zeolites and diatomaceous earth as nano- and micro-carriers respectively. These experiments confirmed the simulated predictions, showing that under the used exposure conditions nano-particles are only able to protect relatively small damages of micron size dimensions. Micron-sized carriers on the other hand allow sufficient release to protect larger damages, even at lower pigment volume concentrations. Additional simulations on rapid electrolyte diffusion pathways inside the coating are also in good agreement with the experiments, indicating the presence of diffusion pathways might play an important role in sustained inhibitor release and corrosion protection at local damages.

This work investigates an integrated analysis of in-situ optical data and time-frequency information from electrochemical potential noise (EPN) data to study the effectiveness and durability of an anodic and cathodic corrosion inhibitor. Two different corrosion inhibiting species, cerium(III) (Ce(III)) and phytic acid (PHA), are tested on aluminum alloy AA2024-T3. Corrosion of AA2024-T3 serves as a negative reference. Time-frequency analysis of EPN data provides a direct insight in the kinetics of the electrochemical processes related to different types of corrosion and/or inhibitor activity over time. The simultaneous, in-situ optical technique allows visualizing and quantifying the surface changes associated with the electrochemical signals. Both Ce(III) and PHA were not capable to inhibit corrosion to a large extent, as re-immersion led to electrochemical (corrosion) activity for both inhibitors. Time-variant changes between corrosion, inhibitor activity, inhibited state and re-activation can effectively be discriminated from each other.

A hyphenated optical-electrochemical technique and image analysis protocol is used to quantify global and local (intermetallic) corrosion process and kinetics. Our findings reveal an early stage (< 60 s) composition-dependent hierarchical local activation of all IMs that can be attributed to IM dealloying. This is followed by local trenching initiated at matrix locations adjacent to regions of the IMs previously dealloyed, which in turn develops into concentric trenching around the IMs. These stages have quantifiable activation times and kinetics. While dealloying kinetics are found to be strongly dependent on IM composition and slightly dependent on IM size in the case of the S-phases, trenching kinetics are IM composition and size independent.

Earlier studies on cerium-loaded naturally occurring silica microparticles (i.e., diatomaceous earth) demonstrated the potential to efficiently protect small scratches in epoxy-coated AA2024-T3 panels during relatively short immersion times. The current work investigates the potential of such inhibitor-loaded microparticles to protect wide and deep scribes (up to 1 mm wide) in long-time immersion testing and during cyclic (wet/dry) conditions. For this, cerium nitrate and 2,5-dimercaptothiadiazole (DMTD) were used as inorganic and organic corrosion inhibitors. The corrosion protection was evaluated using a hyphenated real-time optics/electrochemistry method and two individual local techniques measuring oxygen concentration and electrochemical impedance (LEIM) inside the scribe. SEM/EDS was used to analyze the samples after exposure. The results show significant levels of corrosion protection at damaged locations at low cerium concentrations (3.7 wt % Ce3+ relative to the total coating mass) during 30 days of immersion in salt solution. However, for a given scribe geometry, the protection was found to be dependent on the electrolyte volume with larger electrolyte/exposed metal ratios leading to short protection time. A partial replacement of the Ce3+ by DMTD in the microcarriers resulted in a higher degree of passivation than when DMTD was used alone. Wet/dry cyclic exposure tests showed that cyclic conditions can increase the buildup of stable inhibitor-containing layers in the case of cerium-loaded silica microparticles. This underlines the need for more research using wet/dry exposure conditions.

Real-time optical analysis is used to improve the interpretation of electrochemical noise signals (EN). The concept is presented for the case of AA2024-T3 under immersion in various NaCl concentrations. An in-house developed optical-electrochemical technique allowed for high spatiotemporal resolution and was used to visualize and quantify surface changes in parallel with monitoring EN signals. EN analysis was performed in the time-frequency domain using continuous wavelet transform (CWT). Correlations between the two procedures enabled the identification of corrosion processes in time, such as de-alloying, etching, pitting and subsurface corrosion. Besides this, optical measurements at higher magnification were used to analyse a smaller section of the exposed metal with a spatial resolution below 1 μm. This enabled the quantification on the size, number and nearest neighbor distance of local corrosion events, such as pits and corrosion rings. The set-up and optical protocol allowed for the first time (i) to establish a direct relationship between EN signals and the occurrence of specific localized corrosion phenomena and (ii) an in-situ highly-resolved monitoring of local corrosion processes. As a final result of the optical analysis we introduce a straightforward illustration that allows the direct identification of EN features to macroscopic local corrosion phenomena.

An in-situ hyphenated optical and electrochemical method for the real-time study of corrosion and corrosion inhibition processes is presented and validated for the case of AA2024-T3 exposed to two NaCl concentrations and six inhibitors. During testing, 5 μm resolution optical images of the exposed surface are obtained in parallel to electrochemical impedance measurements using a home-made 3D printed electrochemical cell. This method allowed obtaining both optical and electrochemical information of the studied surface with high time correlation. A data treatment analysis of the optical images was established thereby allowing the identification and quantification of corrosion-features related to intermetallic corrosion (e.g. trenching and meta-stable pitting) and co-operative corrosion (e.g. corrosion-rings, domes and surface-oxides) on a spatiotemporal scale, generally only observed through the use of ex-situ methods such as SEM. In addition, the study of the long-term corrosion inhibition of six inhibitors at concentrations ranging from 10⁻³ M to 10⁻⁶ M allowed quantifying inhibition kinetics as well as identifying different inhibitor and concentration dependent mechanisms (e.g. Cerium and DEDTC vs. Lithium) and decreasing incongruences between impedance and inhibition behaviour (e.g. DMTD). As a result, the use of quantifiable in-situ optical analysis is confirmed as a powerful tool to better interpret electrochemical signals or monitor electrochemical-dependent surface phenomena.

In this work, a new concept is introduced for active corrosion protection at damaged sites aiming at overcoming existing limitations of currently proposed strategies based on dispersed inhibitor-loaded nanocontainers in coatings. The underlying principle is based on the formation of low-density and/or humidity responsive interconnected paths of inhibitor in the coating, what is called inhibiting nanonetworks. Such an approach allows for (on-demand) long-term local supply of corrosion inhibitor at the damage site. For the proof-of-concept, water responsive inhibiting nanonetworks based on polyvinyl alcohol and two known efficient corrosion inhibitors for AA2024-T3 (cerium chloride and lithium carbonate) using electrospinning are developed. The inhibiting nanonetworks are obtained by subsequently embedding the electrospun fiber mats in thermoset epoxy coatings applied on AA2024-T3. The coated panels are scratched and exposed to NaCl solutions for a month while continuously monitoring the protective properties electrochemically and optically in a hyphenated setup. The effect of the corrosion inhibitor type and the partial crosslinking of the mat on release and protection are analyzed. Protection levels at relatively big damaged sites are obtained for at least a month immersion thereby proving the benefits of high inhibitor quantities continuously released in time.

The use of micron sized nanoporous diatom algae exoskeletons for inhibitor storage and sustained corrosion protection of coated aluminium structures upon damage is presented. In this concept the algae exoskeleton allows local inhibitor loading, limits the interaction between the cerium and the epoxy/amine coating and allows for diffusion-controlled release of the inhibitor when needed. The inhibitor release and corrosion protection by loaded exoskeletons was evaluated by UV/Vis spectrometry, a home-built optical-electrochemical setup, and Raman spectroscopy. Although this concept has been proven for a cerium-epoxy-aluminium alloy system the main underlying principle can be extrapolated to other inhibitor-coating-metal systems.