A comparative study of molybdate/silane composite films on galvanized steel with different treatment processes

Abstract Two types of molybdate/silane composite films were obtained on the surface of hot-dip galvanized steel sheets by either directly immersing in a solution containing silane and molybdate as additive (single-step process), or firstly immersing in a molybdate solution, then in a silane solution (two-step process). The chemical compositions and microstructures of the films were examined by scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES) and reflection absorption infrared spectroscopy (RAIR). The corrosion resistances were investigated by electrochemical measurements and neutral salt spray (NSS) test. The results showed that the molybdate/silane composite film formed in the single-step process had a similar double-layer structure as that obtained in the two-step process. The inner layer was composed mainly of the elements O, Mo, Zn, and P, similar to the single molybdate film; whereas the outer layer was composed mainly of the elements C, O and Si, similar to the single silane film. Compared with the single molybdate or silane film, the corrosion current of the composite films was reduced and the impedance of the films was increased. Accordingly, the corrosion resistance of the composite films was remarkably enhanced to a level which was comparable to or even surpassing that of the conventional chromate passivation film.