Described herein is a continuous coil pretreatment process used to treat the surface of an aluminum alloy sheet or coil for subsequent deposition of an acidic organophosphorus compound. The process can include applying a cleaner to a surface of an aluminum sheet or a coil; etching the surface of the aluminum sheet or the coil with an acidic solution; rinsing the surface of the aluminum sheet or the coil with deionized water; applying to the surface of the aluminum sheet or the coil a solution of an acidic organophosphorus compound; rinsing the surface of the aluminum sheet or the coil with deionized water; and drying the surface of the aluminum sheet or the coil.

Described herein is a continuous coil pretreatment process used to treat the surface of an aluminum alloy sheet or coil for subsequent deposition of an acidic organophosphorus compound. The process can include applying a cleaner to a surface of an aluminum sheet or a coil; etching the surface of the aluminum sheet or the coil with an acidic solution; rinsing the surface of the aluminum sheet or the coil with deionized water; applying to the surface of the aluminum sheet or the coil a solution of an acidic organophosphorus compound; rinsing the surface of the aluminum sheet or the coil with deionized water; and drying the surface of the aluminum sheet or the coil.

This disclosure provides corrosion-resistant coatings that significantly improve corrosion resistance compared to the prior art. The corrosion protection system senses gradients in electrical potential, pH, and metal ion concentration, and then automatically halts corrosion. Some variations provide a gradient-responsive corrosion-resistant coating comprising: a first layer comprising a transition metal oxide and mobile cations; a second layer comprising a biphasic polymer, wherein the biphasic polymer contains ionic groups, wherein the biphasic polymer comprises a discrete phase and a continuous transport phase, wherein the continuous transport phase is capable of delivering oligomers in response to corrosion byproducts, and wherein the oligomers are ionically crosslinkable with metal cations from a base metal substrate. Other variations provide a corrosion protection system comprising: a base metallic layer; a metal oxide layer comprising a transition metal oxide and mobile cations; a polymer layer comprising a biphasic polymer; and a sealing layer disposed on the polymer layer.

This disclosure provides corrosion-resistant coatings that significantly improve corrosion resistance compared to the prior art. The corrosion protection system senses gradients in electrical potential, pH, and metal ion concentration, and then automatically halts corrosion. Some variations provide a gradient-responsive corrosion-resistant coating comprising: a first layer comprising a transition metal oxide and mobile cations; a second layer comprising a biphasic polymer, wherein the biphasic polymer contains ionic groups, wherein the biphasic polymer comprises a discrete phase and a continuous transport phase, wherein the continuous transport phase is capable of delivering oligomers in response to corrosion byproducts, and wherein the oligomers are ionically crosslinkable with metal cations from a base metal substrate. Other variations provide a corrosion protection system comprising: a base metallic layer; a metal oxide layer comprising a transition metal oxide and mobile cations; a polymer layer comprising a biphasic polymer; and a sealing layer disposed on the polymer layer.

The disclosure provides compositions and methods for inhibiting corrosion of a copper surface using a bis-imidazoline compound having an aromatic group, such as an aryl bis-imidazoline. The bis-imidazoline corrosion inhibitor can provide one or more advantage in use such as synergistic performance in aqueous and acidic media at low active dosages, resistance to decomposition or degradation in the presence of harsh reagents, ease of dispersion in an aqueous system, and improved thermal stability over conventional triazole based inhibitors. The disclosure also provides methods for the synthesis of bis-imidazoline compounds.

The present disclosure provides an aqueous binder composition for forming a sacrificial corrosion-protective coating, said composition being free of chromates and also preferably free of borates and molybdates. Said binder composition advantageously has a pH of less than 6 and comprises a binder, particles of at least one metal oxide and at least one metallic phosphate, said binder comprising a hydrolyzed organosilane oligomer. In addition, the proportion by weight of said particles of at least one metal oxide relative to the total dry weight of said binder composition is greater than or equal to 75%.

The present disclosure provides an aqueous binder composition for forming a sacrificial corrosion-protective coating, said composition being free of chromates and also preferably free of borates and molybdates. Said binder composition advantageously has a pH of less than 6 and comprises a binder, particles of at least one metal oxide and at least one metallic phosphate, said binder comprising a hydrolyzed organosilane oligomer. In addition, the proportion by weight of said particles of at least one metal oxide relative to the total dry weight of said binder composition is greater than or equal to 75%.

Disclosed is a method of treating a substrate. The surface is contacted with a sealing composition comprising a lithium cation; and optionally, with conversion composition comprising a cation of a lanthanide, a Group IIIB, and/or a Group IVB metal. The conversion composition is applied to provide a film on the substrate surface resulting in a level of the lanthanide, Group IIIB metal, and/or Group IV metal thereon of at least 100 counts greater than on a surface of a substrate that does not have the film thereon as measured by X-ray fluorescence (measured using X-Met 7500, Oxford Instruments; operating parameters 60 second timed assay, 15 Kv, 45 ?A, filter 3, T(p)=1.5 ?s for lanthanides, Group IIIB metals, and Group IVB metals except zirconium; operating parameters 60 second timed assay, 40 Kv, 10 ?A, filter 4, T(p)=1.5 ?s for zirconium). A substrate obtainable by the methods also is disclosed.

Microencapsulated healing agents that, upon incorporation into a zinc-rich coating or coating system, improve the coating or coating system's ability to maintain its adhesion and corrosion resistance after damage that exposes the underlying substrate. These microencapsulated healing agent formulations are uniquely synergistic with zinc-rich coatings, and/or with zinc particles in a zinc rich coating, improving both adhesion maintenance and corrosion resistance following damage that exposes the substrate.

Microencapsulated healing agents that, upon incorporation into a zinc-rich coating or coating system, improve the coating or coating system's ability to maintain its adhesion and corrosion resistance after damage that exposes the underlying substrate. These microencapsulated healing agent formulations are uniquely synergistic with zinc-rich coatings, and/or with zinc particles in a zinc rich coating, improving both adhesion maintenance and corrosion resistance following damage that exposes the substrate.