The effect of pore sealing in a multilayer ▫Si–O–Zr/Al_2O_3▫ coating designed to protect aluminium from corrosionRodič, Peter (Avtor) Kapun, Barbara (Avtor) Milošev, Ingrid (Avtor) aluminumcorrosionhybrid sol-gelatomic layer depositionpore sealingThis study deals with the combination of two corrosion protection strategies for aluminium: barrier protection (provided by a 3.8 μm thick hybrid sol–gel coating) and aluminium pore sealing via the use of a 100 nm thick layer of aluminium oxide. A Si–O–Zr hybrid sol–gel coating (TMZ) was synthesised by combining two separately prepared sols (i) tetraethyl orthosilicate and 3-methacryloxypropyl trimethoxysilane and (ii) zirconium(IV) n-propoxide chelated with methacrylic acid. The synthesis of the Si–O–Zr hybrid sol–gel was evaluated at various stages using real-time infrared spectroscopy. A 100 nm thick Al2O3 film was prepared via thermal atomic layer deposition at 160 °C using trimethyl aluminium and water as precursors. The coating and film properties were assessed via focused ion beam/scanning electron microscopy coupled with energy-dispersive X-ray spectrometry. Sealing with the Al2O3 film did not affect the microstructure and composition of the underlying sol–gel coating. The coating’s corrosion performance in 0.1 M NaCl solution was evaluated using electrochemical impedance spectroscopy. Compared to individual coatings, the multilayer TMZ/Al2O3 coating ensured prolonged (more than three weeks) durable corrosion protection for the aluminium. The impedance magnitude increased by two orders compared to the uncoated substrate (|Z|10 mHz from 16 kΩ cm2 to almost 830 MΩ cm2). Thus, the pore sealing of the sol–gel coating using an ALD alumina film produced a protective multilayer coating system, with |Z|10 mHz remaining above 5 MΩ cm2 after four weeks in NaCl solution.MDPI20232025-04-29 11:29:53Neznano22130UDK: 54ISSN pri članku: 2075-4701DOI: 10.3390/met13121960COBISS_ID: 174730243Švicasl© 2023 by the authors.