2003 Progress Report: Zeolite Coatings by In-Situ Crystallization as an Environmentally Benign Alternative to Chromate Conversion and Anodization Coatings

EPA Grant Number: R828134
Title: Zeolite Coatings by In-Situ Crystallization as an Environmentally Benign Alternative to Chromate Conversion and Anodization Coatings
Investigators: Yan, Yushan
Institution: University of California - Riverside
EPA Project Officer: Richards, April
Project Period: August 1, 2000 through July 31, 2003 (Extended to July 31, 2004)
Project Period Covered by this Report: August 1, 2002 through July 31, 2003
Project Amount: $250,316
RFA: Technology for a Sustainable Environment (1999) RFA Text |  Recipients Lists
Research Category: Nanotechnology , Sustainability , Pollution Prevention/Sustainable Development


The objectives of this research project are to: (1) develop a chromium-free zeolite coating that has comparable thickness to chromate conversion and anodization coatings and equivalent or superior performance in coating adhesion, corrosion protection, abrasion resistance, and paint adhesion; and (2) explore dense polycrystalline high-silica or pure-silica zeolite films in their as-synthesized state for corrosion protection. An intrinsically inexpensive, safe, and nonpolluting in situ crystallization process capable of coating large surfaces that have complex shapes and occupy confined spaces also will be developed during the research project. Zeolites are microporous crystalline silicate materials that have been widely exploited for their microporosity (<15Å), as catalysts, and as separation media. Many high-silica zeolites, however, are nonporous in their as-synthesized state because of the organic molecules occluded in their pores during crystallization. High-silica zeolites also are known for their thermal and chemical stability and high mechanical strength.

Progress Summary:

In Year 1 of the project, we demonstrated that high-silica zeolite ZSM-5 coatings on aluminum alloys and steel are extremely corrosion-resistant in strong acids, bases, and pitting aggressive environments. We also demonstrated that the in situ crystallization coating deposition method we developed is capable of coating surfaces of complex shape and in confined spaces, two key features of an anodization process. We also demonstrated that the ZSM-5 coating has good adhesion and thermal shock stability and performs reasonably well under bending and mechanical impact. It also can be easily painted with widely used polymeric paints.

In Year 2 of the project, we demonstrated that high-silica zeolite coatings are a general approach for providing corrosion protection of aluminum alloys; this is another key milestone for zeolite coating technology. We have shown that high-silica zeolite beta and zeolite MTW both provide good corrosion resistance. A journal article on this has been published, and two technical presentations have been made, one at the 2002 Gordon Research Conference on Zeolites and Layered Materials, and one at the 2002 American Institute of Chemical Engineers Annual Meeting. We have successfully defended our patent, including both the materials and process claims. This comprehensive patent will become a key piece of intellectual property for commercialization efforts. Based on the results of this project, our proposal, in collaboration with the U.S. Navy, U.S. Army, and the University of Massachusetts, in the amount of $1.65 million for 4 years, has been approved by the Strategic Environmental Research and Development Program (SERDP). This will allow us to pursue many key issues facing the technology development.

In Year 3 of the project, we successfully extended the zeolite coating to other aluminum alloys, including 6061 and 7075, and steel 1008 as planned. We also successfully prepared zeolite A and Y coatings on pure aluminum. Another U.S. patent may be filed; we are negotiating with a company, and licensing is possible. We have published a comprehensive review in which corrosion-resistant coatings were one of the major applications. Several related papers have been published. The Principal Investigator was invited to give a lecture on corrosion-resistant zeolite coatings at an international zeolite conference in Japan, although the conference was canceled because of concerns about Severe Acute Respiratory Syndrome (SARS). Several manuscripts are being prepared and will be submitted in the next several months. We have applied for a 1-year, no-cost extension, as we believe that during the next year we will be able to further advance the work and possibly license the patent.

Future Activities:

Future activities for the project are to: (1) submit manuscripts for publication once the study is completed, (2) license patents, (3) license the technology to a commercial company, and (4) further advance the coatings technology.

Journal Articles on this Report : 4 Displayed | Download in RIS Format

Other project views: All 36 publications 19 publications in selected types All 18 journal articles
Type Citation Project Document Sources
Journal Article Cheng X, Wang Z, Yan Y. Corrosion-resistant zeolite coatings by in situ crystallization. Electrochemical and Solid-State Letters 2001;4(5):B23-B26. R828134 (2001)
R828134 (2002)
R828134 (2003)
R828134 (Final)
  • Abstract: ECS - Abstract
  • Journal Article Huang L, Wang H, Hayashi CY, Tian B, Zhao D, Yan Y. Single-strand spider silk templating for the formation of hierarchically ordered mesoporous silica fibers. Journal of Materials Chemistry 2003;13(4):666-668. R828134 (2003)
    R828134 (Final)
  • Abstract: RSC - Abstract
  • Journal Article Li S, Demmelmaier C, Itkis M, Liu Z, Haddon R, Yan Y. Micropatterned oriented zeolite monolayer films by direct in situ crystallization. Chemistry of Materials 2003;15(14):2687-2689. R828134 (2003)
    R828134 (Final)
  • Other: ACS - Citation
  • Journal Article Mitra A, Wang Z, Cao T, Wang H, Huang L, Yan Y. Synthesis and corrosion resistance of high-silica zeolite MTW, BEA and MFI coatings on steel and aluminum. Journal of the Electrochemical Society 2002;149(10):B472-B478. R828134 (2002)
    R828134 (2003)
    R828134 (Final)
  • Abstract: ECS - Abstract
  • Supplemental Keywords:

    corrosion, zeolite, coating, thin film, aluminum, aluminum alloys, steel, chromium, anodization, conversion coating., RFA, Scientific Discipline, Toxics, Water, Sustainable Industry/Business, cleaner production/pollution prevention, Wastewater, Environmental Chemistry, Sustainable Environment, Technology for Sustainable Environment, 33/50, Environmental Engineering, hexavalent chromium, in situ crystallization, environmentally conscious manufacturing, chromium & chromium compounds, cleaner production, zeolites, environmentally benign solvents, alternative materials, anodization coatings, metal plating industry, carcinogenicity, coating processes, innovative technology, microelectronics, water treatment, corrsion protection, pollution prevention, chromium free surface finishing

    Relevant Websites:

    http://www.engr.ucr.edu/~yushan Exit

    Progress and Final Reports:

    Original Abstract
    2001 Progress Report
    2002 Progress Report
    Final Report