Effect of Synthesis Conditions on the Controlled Growth of MgAl–LDH Corrosion Resistance Film: Structure and Corrosion Resistance Properties

In this study, a series of MgAl–layered double hydroxide (LDH) thin films were synthesized by a single step hydrothermal process at different synthetic conditions on AA6082, and the combined effect of reaction temperatures and crystallization times on in situ growth MgAl–LDH structural geometry, growth rate, and more importantly on the corresponding corrosive resistance properties are briefly discussed. The synthesis of LDH was performed at reaction temperatures of 40, 60, 80, and 100 °C, while the treatment time was varied at 12, 18, and 24 h. The as-prepared synthetic coatings were characterized by scanning electron microscopy (SEM), energy dispersion spectroscopy (EDS), X-ray diffraction (XRD) and Fourier transform infrared spectroscopy (FT-IR), while the corresponding corrosion protection efficiency of the developed coating was studied through potentiodynamic polarization studies and electrochemical impedance spectra. The findings demonstrated that extended crystallization time and reaction temperature impart a significant effect on the oriented growth of layered double hydroxide, the surface morphology, and on the film thickness, which had a remarkable influence on the LDH corrosion resistance ability. The LDH coated specimen developed at 100 °C for 18 h reaction time showed a more compact and dense structure compared to the traditional platelet structure obtained at 80 °C for 24 h crystallization time, and interestingly that compact structure exhibited the lowest corrosion current density, up to five orders of magnitude lower than that of bare AA6082.