Adhesion of the plasma polymer of trimethylsilane to aluminum alloys

The adhesion of a plasma polymer and the corrosion protection offered to aluminum alloy substrates depends on the cleanliness of the substrate surface and the state of oxides on the aluminum alloy surface. Both factors are dependent on what type of alloy is used, and consequently, the best preparation of the substrate surface differs on the type of aluminum alloy. Oxygen plasma treatment is effective for the elimination of organic surface contamination, but plasma treatment, such as that of mixed argon and hydrogen, cannot be used to modify the surface state of oxides on these alloys. This is because oxides of aluminum are stable and thus resist plasma modification, and prolonged plasma treatment has been observed to change concentrations of alloy components at the surface due to the heating of the alloy. Chemical cleaning of the surface is necessary before the application of the plasma polymer used for corrosion protection enhancement. Once the surface was properly prepared, a plasma polymer of trimethylsilane (TMS), prepared by cathodic polymerization, adhered well to aluminum alloys investigated in this study. Major adhesive failure, however, occurred as a consequence of reactor contamination when hexafluoroethane (HFE) plasma treatment of initially formed TMS plasma polymers was employed. Plasma pretreatment of the substrate with O-2 or postplasma treatment of the plasma polymer of TMS with Ar (instead of HFE) was effective in eliminating the surface-contamination effect on the adhesion. (C) 2002 Wiley Periodicals, Inc.