Synthesis and Enhanced Corrosion Protection Performance of Reduced Graphene Oxide Nanosheet/ZnAl Layered Double Hydroxide Composite Films by Hydrothermal Continuous Flow Method

Prevention of water, oxygen, and chloride ions contained in hydrotalcite interlayers from diffusing through the layered double hydroxides (LDH) is of crucial importance in corrosion protection. In this work, a hybrid composed of reduced graphene oxide (RGO) nanosheets/Zn²⁺/Al³⁺ layered double hydroxide (RGO/ZnAl-LDH) composite films on the surface of 6N01 aluminum (Al) alloy was successfully synthesized by a novel and facile hydrothermal continuous flow method, which enabled direct growth of the composite on the surface of the Al alloy substrate. The structure and morphology of the RGO/ZnAl-LDH composite films were fully characterized. Based on electrochemical measurements in a NaCl solution, the RGO/ZnAl-LDH composite film significantly enhanced the corrosion protection, as compared with the ZnAl-LDH film. The RGO/ZnAl-LDH composite film could maintain an outstanding corrosion resistance after 7 days immersion in a high concentration of NaCl solution (i.e., 5.0 wt %). The enhanced corrosion resistance was attributed to the barrier effect on diffusion of water, oxygen, and chloride ions by the RGO contained in the RGO/ZnAl-LDH composite films.