Development of ATR-FTIR Kretschmann Spectroscopy for In situ Studies of Metal / Polymer Interfaces : and its Intergration with EIS for Exposure to Corrosive Conditions

Abstract: The environmental stability of a metal / polymer interface is essential for the durability and mechanical stability of constructions in several important areas such as the automotive, offshore, building and aerospace industries. The protective capability of a polymer film is strongly connected to its barrier properties, but the transport of water and corrosive constituents through the polymer and the subsequent processes at the metal surface are complicated to analyse in detail. The surface to be analysed is confined between two media that are impermeable to most probing particles used in conventional analytical techniques. Several methods exist to describe separate parts of the system, but few techniques work atambient pressure and have the capacity to conduct real-time analysis at relevant exposure conditions. In this work, attenuated total reflection Fourier transform infrared spectroscopy (ATR-FTIR) in the Kretschmann geometry was successfully employed for systematic studies of metal / polymer interfaces. This technique requires the use of thin metal films deposited on an internal reflection element (IRE). Most studies were performed on aluminium, which is an important structural light-weight material, but also zinc was analysed, being frequently used for corrosion protection of steel. Upon exposure to water and electrolytes, the ATR-FTIR Kretschmann technique was found capable to monitor and to separate early deterioration related processes at the aluminium / polymer interface, including water sorption and transport of ionic species through the polymer film. Other main processes identified were the formation of corrosion products and swelling of the surface-near polymer network. To perform more comprehensive interpretations, a spectro-electrochemical method was further developed for in situ studies of the hidden metal / polymer interfaces. The ATR-FTIR Kretschmann technique was here combined with the complementary acting technique, Electrical Impedance Spectroscopy (EIS). The integrated set-up was able to provide complementary information, with ATR-FTIR Kretschmann being sensitive to the surface-near region and EIS to the whole system. For instance, metal oxidation and delamination processes can be difficult to distinguish by EIS, while on the other hand oxidation and hydration reactions on aluminiumcan be confirmed as IR bands at distinct positions. Delamination and swelling of a polymer both result in negative bands in an IR spectrum, but these processes may be distinguished by EIS as alterations in different frequency regions. While traditional chemical pre-treatments for enhanced hydrolytic stability perform excellent, they are being phased out from industrial applications due to environmental concerns and work health issues. Today there is an intense ongoing research regarding the mechanisms and performance of environmentally friendly pretreatments to develop systems of similar performance, and the analysis of the confined metal / polymer interface is crucial for this development. The capability of the integrated in situ ATR-FTIR Kretschmann and EIS set-up was therefore further applied to systems where a surface pre-treatment had been applied to the metal prior to the organic coating. Studies were first performed on vacuum-evaporated films of zinc treated with a titanium-based conversion coating and further coated with a UV-curing polymer. Alterations of the conversion layer could be detected upon exposure to the electrolyte. Also alkaline-cleaned aluminium coated with an amino-functional silane film and a thermo-curing epoxy top-coat was thoroughlycharacterized by both ATR-FTIR and IRRAS and further investigated upon exposure toelectrolyte and humid air. Changes at the hidden interface were detected upon thermal curingof the epoxy film and during exposure in electrolyte, and the in situ ATR-FTIR Kretschm annanalysis showed a high sensitivity towards alterations in the interfacial region. Complementary studies in the absence of metal could confirm a water uptake within the silane film and water-induced alterations of the siloxane network.