Catechol/m-Phenylenediamine Modified Sol–Gel Coating with Enhanced Long-Lasting Anticorrosion Performance on 3003 Al Alloy

Aluminum alloys, characterized by their low density and high mechanical strength, are widely applied in the manufacturing sector. However, the application of aluminum alloys in extreme environments presents severe corrosion challenges. Sol-gel organic coating techniques have garnered significant attention due to their excellent stability, barrier properties, and cost-effectiveness, as well as their simpler processing. Nevertheless, conventional sol-gel coatings are unable to withstand the corrosive effects of high-chloride and high-halide ion environments such as marine conditions, owing to their inherent structural defects. Therefore, this study proposes the utilization of a simple method to synthesize catechol (CA) and meta-phenylenediamine (MPD)-derived catecholamine compounds to modify sol-gel coatings. Surface characteristics of the modified coatings were analyzed using Fourier-transform infrared spectroscopy (FT-IR), ultraviolet-visible (UV-Vis) spectroscopy, scanning electron microscopy (SEM), and X-ray photoelectron spectroscopy (XPS). The thickness of the modified coating was approximately 6.8 μm. The CA/MPD-modified substance effectively densifies the sol-gel coating, enhancing its corrosion protection performance. A 3.5 wt% NaCl solution was used to simulate a marine environment, and electrochemical impedance spectroscopy (EIS) was conducted using an electrochemical workstation to evaluate the coating's protective properties over a long-term period. The results indicate that the modified coating provides protection for 3003 aluminum alloy for a minimum of 30 days under corrosive conditions, outperforming unmodified sol-gel coatings in terms of corrosion resistance.