Effect of Redox Mediators on Corrosion Behavior and Scanning Electrochemical Microscopy Response.

Scanning electrochemical microscopy (SECM) is widely used to measure local electrochemical reactivity of corroding surfaces. A major criticism of using SECM in feedback mode for corrosion studies is the requirement of an external redox mediator (RM) as it could react with the metal and affect the Nernst potential at the metal-solution interface. Consequently, it becomes challenging to differentiate the interference caused by the RM from the local reactivity of the metal. Herein, a multiscale electrochemical approach is presented to investigate the effect of RM choice on the corroding substrate. Two common RMs, ferrocenemethanol and hexaammineruthenium(III) chloride, were used to perform SECM over copper and aluminum. It was found during macroscale electrochemical measurements that Ru(NH)63+ acted as an oxidant and promoted corrosion. The SECM feedback behavior varied for copper depending on the RM used, suggesting that the corrosion reactions controlled the negative feedback mechanism, not the formation of an insulating passive film. The passivated aluminum surface consistently exhibited negative feedback, regardless of the RM used. SECM approach curves also displayed a distortion in the steady state current, which was caused by the deposition of substrate-generated species on the microelectrode. These deviations in feedback response were accounted for during analysis through incorporation into a finite element model to accurately extract the RM kinetic rate constants. The importance of understanding these processes is highlighted to avoid misinterpretation of passive behavior and advances toward a more quantitative use of SECM for corrosion studies.

Quantitative Feedback Referencing for Improved Kinetic Fitting of Scanning Electrochemical Microscopy Measurements.

Scanning electrochemical microscopy (SECM) has matured as a technique for studying local electrochemical processes. The feedback mode is most commonly used for extracting quantitative kinetic information. However, approaching individual regions of interest, as is commonly done, does not take full advantage of the spatial resolution that SECM has to offer. Moreover, fitting of experimental approach curves remains highly subjective due to the manner of estimating the tip-to-substrate distance. We address these issues using negative or positive feedback currents as a reference to calculate the tip-to-substrate distance directly for quantitative kinetic fitting of approach curves and line profiles. The method was first evaluated by fitting simulated data and then tested experimentally by resolving negative feedback and intermediate kinetics behavior in a spatially controlled fashion using (i) a flat, binary substrate composed of Au and SiO2 segments and (ii) a dual-mediator system for live-cell measurements. The methodology developed herein, named quantitative feedback referencing (QFR), improves fitting accuracy, removes fitting subjectivity, and avoids substrate-microelectrode contact.

Corrosion of One-Step Superhydrophobic Stainless-Steel Thermal Spray Coatings.

As most superhydrophobic coatings are made of soft materials, the need for harder, more robust films is evident in applications where erosional degradation is of concern. The work herein describes a methodology to produce superhydrophobic stainless-steel thermal spray coatings using the high-velocity oxygen fuel technique. Due to the use of a kerosene fuel source, a carbon-rich film is formed on the surface of the thermal spray coatings, lowering the surface energy of the high-energy metallic substrates. The thermal spray process generates a hierarchical micro-/sub-micro-structure that is needed to sustain superhydrophobicity. The effect of spray parameters such as particle velocity and temperature on the coating's hydrophobicity state was explored, and a high particle velocity was shown to cause superhydrophobic characteristics. The coatings were characterized using scanning electron microscopy, profilometry, X-ray photoelectron spectroscopy, static water contact angle measurements, water droplet roll-off measurements, and water droplet bouncing tests. The corrosion behavior of the coatings was studied using potentiodynamic polarization measurements in order to correlate water repellency with corrosion resistance; however, all coatings demonstrated active corrosion without passivation. This study describes an interesting phenomenon where superhydrophobicity does not guarantee corrosion resistance and discusses alternative applications for such materials.

Fabrication of carbon, gold, platinum, silver, and mercury ultramicroelectrodes with controlled geometry.

A simple, fast, and reproducible method for the fabrication of disk ultramicroelectrodes (UMEs) with controlled geometry is reported. The use of prepulled soda-lime glass capillaries allows one to bypass the irreproducible torch-sealing and experimentally challenging tip-sharpening steps used in conventional fabrication protocols. A micron-sized electroactive wire is sealed inside this capillary producing UMEs with a highly reproducible geometry. Total fabrication time (1 h) and experimental difficulty are significantly reduced. Disk UMEs with various diameters and cores were fabricated, including carbon fiber (7 and 11 µm), gold (10 and 25 µm), platinum (10 and 25 µm), silver (25 µm), and mercury (25 µm). The ratio of the insulating sheath to the electroactive core of the UMEs was 2.5-3.6. Silver UMEs were also used to produce a Ag/AgCl microreference electrode. This general fabrication method can readily be applied to other electroactive cores and could allow any research group to produce high quality disk UMEs, which are a prerequisite for quantitative scanning electrochemical microscopy.