Chromate conversion coating on aluminum alloys - I. Formation mechanism

The formation of chromate conversion coatings (CCCs) on commercially pure Al (AA1050) during immersion in a chromic/ hydrofluoric acid solution has been investigated. A film formation mechanism is proposed based on the combination of open circuit potential measurements and surface analysis techniques, such as Auger electron spectroscopy and atomic force microscopy. It is suggested that the conversion of the Al surface takes place in three distinct stages: activation of the surface, initiation of the film formation, and growth of the conversion layer. In addition to the classical approach, a sol-gel model was considered for the initiation and growth of the film. The effect of the free fluoride and chromic acid concentration was studied using a thermodynamic model, whereas the influence of the Al oxide film was investigated by forming an anodic barrier layer prior to the conversion process. It was shown that the rate-determining step in the CCC formation is the activation of the Al surface. Therefore, the morphology and structure of the conversion layer is determined not only by the bath composition but also by the thickness of the Al oxide film. (C) 2004 The Electrochemical Society.