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Electrodeposited coatings, even those deposited from solutions containing chloride ions and H2O2, were also free of subsurface crevices.
Focused ion beam milling revealed the presence of subsurface crevices underneath a small fraction (∼ 10%) of coated areas, typically in areas with large cracks through the coatings.
Thus, coatings free of subsurface crevices could be produced by using cerium nitrate instead of cerium chloride in the coating solution.
Subsurface crevices were found under craters and regions with large cracks, which were fewer for coatings on Na2CO3 activated substrates compared to coatings on NaOH activated substrates.
The processing variables that contributed to the formation of subsurface crevices under cerium-based conversion coatings on AA 2024-T3 were investigated.
As a result, subsurface crevices are not inherent to cerium-based conversion coatings, but rather were formed due to certain process parameters, specifically the presence of chloride ions and hydrogen peroxide in the coating solution.
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