Liquid-phase shear exfoliation of graphite and its application as corrosion protection coating on aluminum substrate

Although aluminum (Al) or its alloys are moderately protected by a native oxide layer, the presence of chloride ions in aqueous media in direct contact causes pitting attacks and accelerates corrosion. Using graphene as a coating protector can obstruct corrosion due to its numerous chemical and physical properties. This study investigates corrosion protection of Al using graphene nanosheets (GNSs) produced by liquid phase shear exfoliation method (LPE). To do so, few layer-thick graphene nanosheet colloidal solutions were produced by a scalable eco-friendlier lower cost approach. The GNSs were thoroughly characterized using complementary characterization techniques to determine its quality. Spectroscopic and microscopic analyses indicate the synthesis of few-layers graphene (≤ 5 layers) with a high quality. Once approved, the colloidal solution of GNSs was spread over Al substrate by spray coating method, widely used in industrial manufacturing. Raman and near infrared spectroscopies, X-ray diffraction, microscopy techniques including scanning electron, transmission electron and atomic force microscopies were used to investigate morphological and structural behavior of coated GNSs films either on glass or Al substrates. Density functional theory (DFT) calculations revealed the interaction between the two materials is of the physisorption type, with almost no charge transfer and almost no effect of the number of graphene layers. Electrochemical measurements enabled to investigate the corrosion resistance of GNSs films and its stability over time in a 0.5 M sodium chloride (NaCl) solution, similar to marine surroundings. It was found that introducing a GNSs film can indeed reduce the corrosion rate and preserve Al substrate for an extended period.