當陶瓷披覆於金屬材料時，會有熱及機械應力的產生，容易造成陶瓷鍍膜開裂或附著性不佳等問題。為減少該應力，本研究參考成長積層的概念，以陽極處理法於304不銹鋼表面先形成一氧化物層，再進行氧化鋯薄膜的浸鍍，以探討氧化物層與氧化鋯間的接合是否有利於鍍膜品質的改善。
為形成氧化物層，本研究中304不銹鋼是被置於5M H2SO4與5M HNO3之混合酸液中，並施加不同時間(5 min、10 min、20 min)的陽極處理(定電壓或方波脈衝)，以促進氧化物層成長，隨後再以浸鍍法披覆氧化鋯薄膜。304不銹鋼經陽極處理與氧化鋯浸鍍後所形成之薄膜，其表面形貌、厚度與組成以及機械特性是以SEM、AFM、XPS、奈米壓痕機及恆電位儀檢測，而電化學性質差異之比較，是於模擬人體液的環境下進行。
表面形貌之分析結果顯示，不銹鋼經陽極處理後可於其表面形成一層多孔性的鉻鐵礦氧化物層，且伴隨著晶界腐蝕的發生；其腐蝕程度隨著陽極處理時間的增長而趨於嚴重。未經陽極處理的304不銹鋼，其表面之氧化鋯薄膜易因熱膨脹係數的差異而產生裂痕；而經陽極處理者，其氧化鋯薄膜是披覆於一層鉻鐵礦氧化物層上，其薄膜開裂情況可因而獲得改善。
藉由開路電位及極化曲線的量測可知，陽極處理所形成的鉻鐵礦氧化物層因其表面粗糙不均，於模擬人體液中未能提供基材較好的保護性，然而此氧化物層比起原本不銹鋼表面上的鈍化膜擁有較高的鉻含量，可提升304不銹鋼抵抗孔蝕發生的能力。在交流阻抗分析中，於相角對頻率圖譜之高頻處出現的第一個時間常數，為代表氧化鋯薄膜產生之電阻電容並聯反應；在低頻處出現的第二個時間常數，則與304不銹鋼在大氣下形成的鈍化層或陽極處理形成的鉻鐵礦氧化膜有關。
奈米壓痕試驗之結果則顯示鉻鐵礦氧化膜之量測硬度值較氧化鋯薄膜與304不銹鋼者為低，也意味著304不銹鋼在經過不同時間的陽極處理(鉻鐵礦氧化層厚度的改變)之後，在不同的壓痕深度下也將呈現不同的硬度。

In ceramics/metal joining and coating, the most challenging and fascinating issue is how to overcome poor adhesion and cracking in the ceramic/metal materials caused from thermal and mechanical stress. There is an attempt that subsequent anodizing of oxide films can have an oxide/oxide joining (zirconia by dip coating) promising support a concept called “growing integration layer [GIL]”. The aim of this study was to characterize the oxide films grown with different thickness and morphology on 304 stainless steel surface for GIL purposes.
The oxide films were prepared on the surface of 304 stainless steel by anodizing (containing constant potential and square wave pulse) was in 5M H2SO4 and 5M HNO3 for 5、10、20 min. The morphology, thickness, composition, corrosion behavior in Hank’s solution and mechanical properties of oxide films and zirconia films were obtained by SEM, AFM, XPS depth profiles, potentiostat and nanoindentation.
The morphology results showed that a porous FeCr2O4 layer and intergranular corrosion was formed on the surface of 304 SS anodized in acidic solution. Both corrosion and roughness got more seriously as a function of anodizing time. Cracks were found when ZrO2 film coated on the 304 SS substrate due to the difference of thermal expansion between film and substrate. However, a non-crack ZrO2 film could be formed, on the surface of FeCr2O4 layer obtained by square wave pulse, with proper processing time.
In terms of electrochemical measurements, the FeCr2O4 film was less protective from Hank’s solution than the naturally grown passive film because of its rougher surface, but it increased the pitting resistance to corrosion, which was attributed Cr enrichment in the film. In phase angle plots of impedance spectra, a first time constant revealing at high frequency represented a parallel reaction of resistors and capacitors from the formation of ZrO2 film, and a second time constant at low frequency associated with the passive layer or FeCr2O4 film.
Nanoindentation measurements indicated that the hardness values of FeCr2O4 film was smaller than ZrO2 film or 304 stainless steel. It means that the 304 stainless steel with different processing times of anodizing (thickness changes of FeCr2O4 film layer at the ZrO2 film / 304 SS substrate interface) would show the varied hardness in different indentation depth.

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