Novel repair method for technical enamels based on sol–gel and sol-dispersion coatings

Abstract

The aim of the work presented here is the development of a novel repair method for technical enamels by using chemical nanotechnology. Good adhesion of coatings requires good wettability of the substrate by the repair solution. This was achieved by different pre-treatments of the steel substrates. Low sintering temperatures of the coatings can be ensured by the use of nanoparticle-based systems. Based on liquid metal alkoxides, a colloidal alumina sol and metal salts homogeneous sols with up to seven enamel compounds were prepared. The sols were brush coated onto plain and partly enamelled steel substrates and sintered in a furnace, by inductive heating or an IR emitter. Thin (single layer ≪ 1µm) crack-free layers were obtained on nearly all substrates independent of the sintering conditions investigated. The local sintering methods (IR emitter, inductive heating) allow to produce multiple coating systems in short times. Electrochemical impedance spectroscopy (EIS) provides evidence of the protective effect of these layers compared to the bare substrate, but as a result of their chemical composition the layers are not stable in the electrolytic environment for longer times. The thickness of such multiple coatings (20 layers, ≈ 8 µm) is still small compared to that of a technical enamel. Therefore, sol dispersion systems containing powder particles and sol components are applied on top of the sol–gel layers to increase the thickness of the sintered layers.