Corrosion resistant coating fabrication through synergies between SiOC conversion and iron oxidation at high temperatures
Source abstract
Abstract
Abstract High-temperature organic coatings protect assets well at moderately elevated temperatures. However, they degrade severely at higher temperatures (e.g., above 450 °C), leaving little or no corrosion protection to the substrate. Here we report a new approach to making high-temperature hybrid coatings through an open-to-air on-substrate thermal treatment that converts an ambient-cured polysiloxane film to a SiOC glassy ceramic film. During the treatment, iron oxidation products synergistically participate in forming the final coherent and adherent film. Characterization of the hybrid coating, especially its chemical composition evolution, reveals that the organic-inorganic conversion goes through three stages. Together with the plasticizing glass fillers, the SiOC conversion and substrate oxidation process resulted in a defect-free corrosion-resistant SiOC barrier film that maintains corrosion resistance even after being subjected to heat treatment at 760 °C for 1 h. This new approach expands SiOC coatings’ applications in extreme environments previously limited by their complex fabrication process.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced ceramic materials synthesis · Advanced materials and composites · Semiconductor materials and devices
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (84)
Show source-provided references
1. Schütze, M., Malessa, M., Rohr, V. & Weber, T. Development of coatings for protection in specific high temperature environments. Surf. Coat. Technol. 201, 3872–3879 (2006).10.1016/j.surfcoat.2006.07.262 ↗
2. Guo, L. et al. Progress on high-temperature protective coatings for aero-engines. Surf. Sci. Technol. 1, 6 (2023).10.1007/s44251-023-00005-6 ↗
3. Iqbal, H. M. S., Bhowmik, S. & Benedictus, R. Performance evaluation of polybenzimidazole coating for aerospace application. Prog. Org. Coat. 105, 190–199 (2017).10.1016/j.porgcoat.2017.01.005 ↗
4. Vinothkannan, M., Son, B. & Shanmugam, S. Porous gC3N4–Gd2Zr2O7 enables the high-temperature operation of nafion membranes in polymer electrolyte fuel cells over 500 hours. J. Mater. Chem. A 10, 8975–8988 (2022).10.1039/D2TA00483F ↗
5. Thi Khuat, K.-V. et al. Cross-linked polyimide nanofibrous aerogels with hierarchical cellular structure for thermal insulation. ACS Appl. Polym. Mater. 5, 4767–4779 (2023).10.1021/acsapm.3c00335 ↗
6. Han, J., Gao, H., Liu, X., Shang, Y. & Zhang, H. Improving the high-temperature performance by constructing restricted amorphous regions in PEEK. Polym. Degrad. Stab. 220, 110632 (2024).10.1016/j.polymdegradstab.2023.110632 ↗
7. Guo, F. et al. Preparation and characterization of thermo-processable poly(benzimidazole imide)s with soluble and high heat-resistance containing n-phenyl-benzimidazole. Polymer 301, 127017 (2024).10.1016/j.polymer.2024.127017 ↗
8. Nemati, N., Emamy, M., Yau, S., Kim, J.-K. & Kim, D.-E. High temperature friction and wear properties of graphene oxide/polytetrafluoroethylene composite coatings deposited on stainless steel. RSC Adv 6, 5977–5987 (2016).10.1039/C5RA23509J ↗
9. Meng, X., Liu, Y., Huang, M. & Cao, J.-P. Flexible perfluoroalkoxy films filled with carbon nanotubes and their electric heating property. J. Appl. Polym. Sci. 134 (2017).10.1002/app.44782 ↗
10. Zhang, H.-Y., Yuan, L.-L., Hong, W.-J. & Yang, S.-Y. Improved melt processabilities of thermosetting polyimide matrix resins for high temperature carbon fiber composite applications. Polymers 14, 965 (2022).10.3390/polym14050965 ↗
11. Günthner, M. et al. High performance environmental barrier coatings, Part I: passive filler loaded SiCN system for steel. J. Eur. Ceram. Soc. 31, 3003–3010 (2011).10.1016/j.jeurceramsoc.2011.05.027 ↗
12. Torrey, J. D. & Bordia, R. K. Processing of polymer-derived ceramic composite coatings on steel. J. Am. Ceram. Soc. 91, 41–45 (2008).10.1111/j.1551-2916.2007.02019.x ↗
13. Günthner, M. et al. Advanced coatings on the basis of Si(C)N precursors for protection of steel against oxidation. J. Eur. Ceram. Soc. 29, 2061–2068 (2009).10.1016/j.jeurceramsoc.2008.11.013 ↗
14. Li, F. et al. Enhancing oxidation resistance of PCS-derived ceramic coatings on titanium alloys by SiC whiskers. Corros. Sci. 244, 112670 (2025).10.1016/j.corsci.2024.112670 ↗
15. Jacobson, N. S., Opila, E. J. & Lee, K. N. Oxidation and corrosion of ceramics and ceramic matrix composites. Curr. Opin. Solid State Mater. Sci. 5, 301–309 (2001).10.1016/S1359-0286(01)00009-2 ↗
16. Colombo, P., Mera, G., Riedel, R. & Sorarù, G. D. Polymer-derived ceramics: 40 years of research and innovation in advanced ceramics. J. Am. Ceram. Soc. 93, 1805–1837 (2010).10.1111/j.1551-2916.2010.03876.x ↗
17. Bawane, K., Lu, K., Li, Q. & Bordia, R. High temperature oxidation behaviors of SiON coated AISI 441 in Ar+O2, Ar+H2O, and Ar+CO2 atmospheres. Corros. Sci. 166, 108429 (2020).10.1016/j.corsci.2020.108429 ↗
18. Barroso, G., Li, Q., Bordia, R. K. & Motz, G. Polymeric and ceramic silicon-based coatings—a review. J. Mater. Chem. A 7, 1936–1963 (2019).10.1039/C8TA09054H ↗
19. Kim, K. J., Eom, J.-H. & Kim, Y.-W. Processing and structural characteristics of encapsulated ZnO in porous polysiloxane-derived ceramics. J. Ceram. Soc. Jpn. 119, 136–139 (2011).10.2109/jcersj2.119.136 ↗
20. Saha, A. & Raj, R. Crystallization maps for SiCO amorphous ceramics. J. Am. Ceram. Soc. 90, 578–583 (2007).10.1111/j.1551-2916.2006.01423.x ↗
21. Xu, T., Ma, Q. & Chen, Z. High-temperature behavior of silicon oxycarbide glasses in air environment. Ceram. Int. 37, 2555–2559 (2011).10.1016/j.ceramint.2011.03.053 ↗
22. Colombo, P. Polymer Derived Ceramics: From Nano-Structure to Applications (DEStech Publications, Inc, 2010).
23. Mujib, S. B. et al. Electrospun SiOC ceramic fiber mats as freestanding electrodes for electrochemical energy storage applications. Ceram. Int. 46, 3565–3573 (2020).10.1016/j.ceramint.2019.10.074 ↗
24. Packirisamy, S., Sreejith, K. J., Devapal, D. & Swaminathan, B. in Handbook of Advanced Ceramics and Composites: Defense, Security, Aerospace and Energy Applications (eds Mahajan, Y. R. & Johnson, R.) 975–1080 (Springer International Publishing, 2020).10.1007/978-3-030-16347-1_31 ↗
25. Bura, R., Kumar, B. & Prasad, R. M. Polymer-Dderived SiOC ceramic coating for corrosion protection. Int. J. Appl. Ceram. Technol. 21, 900–909 (2024).10.1111/ijac.14588 ↗
26. You, Q. et al. Amorphous SiOC-coated submicron mullite aerogels with excellent thermal and structural stability up to 1500 °C. J. Eur. Ceram. Soc. 45, 117079 (2025).10.1016/j.jeurceramsoc.2024.117079 ↗
27. Bik, M. et al. Optimization of the formation of coatings based on SiAlOC glasses via structural, microstructural and electrochemical studies. Electrochimica Acta 309, 44–56 (2019).10.1016/j.electacta.2019.04.080 ↗
28. Greil, P. Active-filler-controlled pyrolysis of preceramic polymers. J. Am. Ceram. Soc. 78, 835–848 (1995).10.1111/j.1151-2916.1995.tb08404.x ↗
29. Yang, X., Jiang, P., Sun, F., Yang, L. & Fan, X. A pyrolysis heating rate based pressureless method for preparing dense and crack-free polymer-derived silicon oxycarbide bulk ceramics. Ceram. Int. 46, 10392–10399 (2020).10.1016/j.ceramint.2020.01.037 ↗
30. Wang, L., Lu, K. & Ma, R. Effects of different polymer precursors on the characteristics of SiOC bulk ceramics. Appl. Phys. A 125, 395 (2019).10.1007/s00339-019-2680-z ↗
31. Martínez-Crespiera, S., Ionescu, E., Kleebe, H.-J. & Riedel, R. Pressureless synthesis of fully dense and crack-free SiOC bulk ceramics via photo-crosslinking and pyrolysis of a polysiloxane. J. Eur. Ceram. Soc. 31, 913–919 (2011).10.1016/j.jeurceramsoc.2010.11.019 ↗
32. Günthner, M. et al. Particle-filled PHPS silazane-based coatings on steel. Int. J. Appl. Ceram. Technol. 6, 373–380 (2009).10.1111/j.1744-7402.2008.02346.x ↗
33. Wang, X., Hu, J., Li, J., Li, Y. & Xu, C. Processing and properties of Cfibre/SiCfillers/SiOC composites using solvent free liquid polysiloxane as matrix source. Adv. Appl. Ceram. 112, 471–477 (2013).10.1179/1743676113Y.0000000102 ↗
34. Labrousse, M., Nanot, M., Boch, P. & Chassagneux, E. Ex-polymer SiC coatings with Al2O3 particulates as filler materials. Ceram. Int. 19, 259–267 (1993).10.1016/0272-8842(93)90058-Y ↗
35. Rocha, R. M., Bressiani, J. C. & Bressiani, A. H. A. Ceramic substrates of β-SiC/SiAlON composite from preceramic polymers and Al–Si fillers. Ceram. Int. 40, 13929–13936 (2014).10.1016/j.ceramint.2014.05.114 ↗
36. Scheffler, M. et al. Polymer/filler derived NbC composite ceramics. J. Mater. Sci. 38, 4925–4931 (2003).10.1023/B:JMSC.0000004415.23316.b0 ↗
37. Hönack, F. & Riedel, R. Influence of Ti-based fillers on the thermal decomposition and phase development of polysiloxane derived materials. Adv. Eng. Mater. 5, 122–125 (2003).10.1002/adem.200390018 ↗
38. Alvi, S. A. & Akhtar, F. High temperature tribology of polymer derived ceramic composite coatings. Sci. Rep. 8, 15105 (2018).10.1038/s41598-018-33441-8 ↗
39. Lenz Leite, M. et al. Synthesis and characterization of yttrium and ytterbium silicates from their oxides and an oligosilazane by the PDC route for coating applications to protect Si3N4 in hot gas environments. J. Eur. Ceram. Soc. 37, 5177–5191 (2017).10.1016/j.jeurceramsoc.2017.04.034 ↗
40. Tian, Z., Zhu, W., Yan, X. & Su, D. Passive filler-loaded silicon oxycarbide coating on nickle alloy with high thermal shocking behavior and oxidation resistance. Materials 15, 6395 (2022).10.3390/ma15186395 ↗
41. Petríková, I. et al. Passive filler loaded polysilazane-derived glass/ceramic coating system applied to AISI 441 stainless steel, Part 1: processing and characterization. Int. J. Appl. Ceram. Technol. 17, 998–1009 (2020).10.1111/ijac.13417 ↗
42. Nguyen, M. D. et al. Novel polymer-derived ceramic environmental barrier coating system for carbon steel in oxidizing environments. J. Eur. Ceram. Soc. 37, 2001–2010 (2017).10.1016/j.jeurceramsoc.2016.12.049 ↗
43. Donald, I. W. Preparation, properties and chemistry of glass- and glass-ceramic-to-metal seals and coatings. J. Mater. Sci. 28, 2841–2886 (1993).10.1007/BF00354689 ↗
44. Schütz, A., Günthner, M., Motz, G., Greißl, O. & Glatzel, U. Characterisation of novel precursor-derived ceramic coatings with glass filler particles on steel substrates. Surf. Coat. Technol. 207, 319–327 (2012).10.1016/j.surfcoat.2012.07.013 ↗
45. Niu, M. et al. Oxidation behavior of dense SiOC monolithics: the oxide scale development. Corros. Sci. 163, 108235 (2020).10.1016/j.corsci.2019.108235 ↗
46. Raman, R. K. S., Gleeson, B. & Young, D. J. Laser Raman spectroscopy: a technique for rapid characterisation of oxide scale layers. Mater. Sci. Technol. 14, 373–376 (1998).10.1179/mst.1998.14.5.373 ↗
47. Sun, W., Tieu, A. K., Jiang, Z., Zhu, H. & Lu, C. Oxide scales growth of low-carbon steel at high temperatures. J. Mater. Process. Technol. 155–156, 1300–1306 (2004).10.1016/j.jmatprotec.2004.04.172 ↗
48. Chen, R. Y. & Yeun, W. Y. D. Review of the high-temperature oxidation of iron and carbon steels in air or oxygen. Oxid. Met. 59, 433–468 (2003).10.1023/A:1023685905159 ↗
49. Rahimi, H., Mozaffarinia, R. & Hojjati Najafabadi, A. Corrosion and wear resistance characterization of environmentally friendly sol–gel hybrid nanocomposite coating on AA5083. J. Mater. Sci. Technol. 29, 603–AA5608 (2013).10.1016/j.jmst.2013.03.013 ↗
50. Chen, Z., Wu, L. Y. L., Chwa, E. & Tham, O. Scratch resistance of brittle thin films on compliant substrates. Mater. Sci. Eng. A 493, 292–298 (2008).10.1016/j.msea.2007.07.099 ↗
51. Liu, C. et al. High temperature structure evolution of macroporous SiOC ceramics prepared by a sol–gel method. Ceram. Int. 41, 11091–11096 (2015).10.1016/j.ceramint.2015.05.056 ↗
52. Das, G. et al. Study of the pyrolysis process of an hybrid CH3SiO1.5 gel into a SiCO glass. Vib. Spectrosc. 45, 61–68 (2007).10.1016/j.vibspec.2007.07.001 ↗
53. Hansda, S. et al. Structural and optical properties of silicon oxycarbide thin films using silane based precursors via sol-gel process. Thin Solid Films 791, 140226 (2024).10.1016/j.tsf.2024.140226 ↗
54. Bik, M. et al. SiAlOC glasses derived from sol-gel synthesized ladder-like silsesquioxanes. Ceram. Int. 45, 1683–1690 (2019).10.1016/j.ceramint.2018.10.047 ↗
55. Yang, C. S., Yu, Y. H., Lee, K.-M., Lee, H.-J. & Choi, C. K. Investigation of low dielectric carbon-doped silicon oxide films prepared by PECVD Using Methyltrimethoxysilane Precursor. Thin Solid Films 506–507, 50–54 (2006).10.1016/j.tsf.2005.08.032 ↗
56. Litwinek-Rozbicka, E. et al. Structural studies on the low-melting boron frits modified with bismuth (III) oxide. J. Mol. Struct. 1223, 128979 (2021).10.1016/j.molstruc.2020.128979 ↗
57. Partyka, J., Sitarz, M., Leśniak, M., Gasek, K. & Jeleń, P. The effect of SiO2/Al2O3 ratio on the structure and microstructure of the glazes from SiO2–Al2O3–CaO–MgO–Na2O–K2O System. Spectrochim. Acta. A: Mol. Biomol. Spectrosc. 134, 621–630 (2015).10.1016/j.saa.2014.06.068 ↗
58. Inde, H., Kanezashi, M., Nagasawa, H., Nakaya, T. & Tsuru, T. Tailoring a thermally stable amorphous SiOC structure for the separation of large molecules: the effect of calcination temperature on SiOC structures and gas permeation properties. ACS Omega 3, 6369–6377 (2018).10.1021/acsomega.8b00632 ↗
59. Petcharoen, K. & Sirivat, A. Synthesis and characterization of magnetite nanoparticles via the chemical Co-precipitation method. Mater. Sci. Eng. B 177, 421–427 (2012).10.1016/j.mseb.2012.01.003 ↗
60. Liu, H. et al. Tuning mechanical and corrosion performance of SiOC glass coatings prepared by thermal MOCVD. J. Non-Cryst. Solids 579, 121378 (2022).10.1016/j.jnoncrysol.2021.121378 ↗
61. Pan, J. et al. Synthesis of hierarchical porous silicon oxycarbide ceramics from preceramic polymer and wood biomass composites. J. Eur. Ceram. Soc. 34, 249–256 (2014).10.1016/j.jeurceramsoc.2013.08.004 ↗
62. Swain, I. P., Sadual, N. & Behera, S. K. Porosity and nanostructure of silicon oxycarbide derived carbon. Open Ceram 6, 100116 (2021).10.1016/j.oceram.2021.100116 ↗
63. Jing, W., Tariq, N. ul H. & Tang, M. Research progress on SiMOC coatings prepared by polymer pyrolysis and chemical vapor deposition. Heat Treat. Surf. Eng. 5, 2173046 (2023).10.1080/25787616.2023.2173046 ↗
64. Yan, L., Bing, J. & Wu, H. The behavior of ozone on different iron oxides surface sites in water. Sci. Rep. 9, 14752 (2019).10.1038/s41598-019-50910-w ↗
65. Tijing, L. D. et al. Efficacy of zinc and tourmaline in mitigating corrosion of carbon steel in non-flow mode. Chem. Pap. 67, 1304–1310 (2013).10.2478/s11696-013-0387-8 ↗
66. Wu, Z. et al. SiOC nanolayers directly-embedded in graphite as stable anode for high-rate lithium ion batteries. Chem. Eng. J. 375, 121997 (2019).10.1016/j.cej.2019.121997 ↗
67. Bashouti, M. Y. et al. Silicon nanowires terminated with methyl functionalities exhibit stronger Si–C bonds than equivalent 2D surfaces. Phys. Chem. Chem. Phys. 11, 3845–3848 (2009).10.1039/b820559k ↗
68. Anand, R. & Lu, K. Understanding thermodynamic stability and carbothermal reduction in SiOC. Mater. Chem. Phys. 316, 129123 (2024).10.1016/j.matchemphys.2024.129123 ↗
69. Puniredd, S. R., Assad, O. & Haick, H. Highly stable organic modification of Si(111) surfaces: towards reacting Si with further functionalities while preserving the desirable chemical properties of Full Si−C atop site terminations. J. Am. Chem. Soc. 130, 9184–9185 (2008).10.1021/ja800855s ↗
70. Krajewski, M. et al. High temperature oxidation of iron–iron oxide core–shell nanowires composed of iron nanoparticles Phys. Chem. Chem. Phys. https://pubs.rsc.org/en/content/articlelanding/2016/cp/c5cp07569f.10.1039/C5CP07569F ↗
71. Roualdes, S., Berjoan, R. & Durand, J. 29Si NMR and Si2p XPS correlation in polysiloxane membranes prepared by plasma enhanced chemical vapor deposition. Sep. Purif. Technol. 25, 391–397 (2001).10.1016/S1383-5866(01)00067-3 ↗
72. Fu, C., Zhao, G., Zhang, H. & Li, S. A facile route to controllable synthesis of Fe3O4/graphene composites and their application in lithium-ion batteries. Int. J. Electrochem. Sci. 9, 46–60 (2014).10.1016/S1452-3981(23)07697-6 ↗
73. Fan, Y. et al. Corrosion behaviors of carbon steel and Ni-advanced weathering steel exposed to tropical marine atmosphere. J. Mater. Eng. Perform. 29, 6417–6426 (2020).10.1007/s11665-020-05153-6 ↗
74. Hou, Z., Yan, P., Sun, B., Elshekh, H. & Yan, B. An excellent soft magnetic Fe/Fe3O4-FeSiAl composite with high permeability and low core loss. Results Phys 14, 102498 (2019).10.1016/j.rinp.2019.102498 ↗
75. Khanna, A. S. Introduction to High Temperature Oxidation and Corrosion (ASM International, 2002).
76. Bierwagen, G. P. & Rich, D. C. The critical pigment volume concentration in latex coatings. Prog. Org. Coat. 11, 339–352 (1983).10.1016/0033-0655(83)85007-9 ↗
77. Wang, J., Xu, H., Battocchi, D. & Bierwagen, G. The determination of critical pigment volume concentration (CPVC) in organic coatings with fluorescence microscopy. Prog. Org. Coat. 77, 2147–2154 (2014).10.1016/j.porgcoat.2013.12.010 ↗
78. Asbeck, W. K. & Loo, M. V. Critical pigment volume relationships. Ind. Eng. Chem. 41, 1470–1475 (1949).10.1021/ie50475a042 ↗
79. Wiering, L., Qi, X. & Battocchi, D. Corrosion performance of high-temperature organic coatings subjected to heat treatments. Prog. Org. Coat. 159, 106418 (2021).10.1016/j.porgcoat.2021.106418 ↗
80. Sorarù, G. D., Dallapiccola, E. & D’Andrea, G. Mechanical characterization of sol–gel-derived silicon oxycarbide glasses. J. Am. Ceram. Soc. 79, 2074–2080 (1996).10.1111/j.1151-2916.1996.tb08939.x ↗
81. Teter, D. M. & Hemley, R. J. Low-compressibility carbon nitrides. Science 271, 53–55 (1996).10.1126/science.271.5245.53 ↗
82. Zheng, Y., Liu, J., Liang, J., Jaroniec, M. & Qiao, S. Z. Graphitic carbon nitride materials: controllable synthesis and applications in fuel cells and photocatalysis. Energy Environ. Sci. 5, 6717–6731 (2012).10.1039/c2ee03479d ↗
83. Greil, P. Polymer derived engineering ceramics. Adv. Eng. Mater. 2, 339–348 (2000).10.1002/1527-2648(200006)2:6<339::AID-ADEM339>3.0.CO;2-K ↗
84. Soliman, H. M. et al. Effect of differential thermal expansion coefficient on stresses generated in coating. J. Mater. Sci. Technol. 15, 457 (1999).