Characterization of blisters on powder coated aluminium AA5006 architectural profiles

Giorgio Giovanni Battista Zaffaroni*, Visweswara Chakravarthy Gudla, Rameez Ud Din, Rajan Ambat

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review


Investigation of premature blistering and delamination of coated AA5006 window frames using scanning (SEM) and transmission electron microscopy (TEM), glow discharge optical emission spectroscopy, and X-ray photoelectron spectroscopy (XPS )is presented. SEM of the blisters revealed corrosion of Aluminium and accumulation of corrosion products at the interface of coating and metal. TEM and XPS analysis revealed a thin and non-homogenous hexavalent Cr conversion layer. High number density of intermetallics, and surface defects from metal forming process resulted in a defective conversion coating leading to reduced corrosion protection of aluminium in the presence of water and Cl from atmosphere.

Original languageEnglish
JournalEngineering Failure Analysis
Pages (from-to)347-360
Publication statusPublished - 2019


  • Aluminium
  • Blistering
  • Corrosion
  • Interface analysis
  • Intermetallics

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