Electrodeposition of Al-Zr alloys from lewis acidic aluminum chloride-1-ethyl-3-methylimidazolium chloride melt

The electrochemistry of Zr(IV) and Zr(II) and the electrodeposition of Al-Zr alloys were examined in the Lewis acidic 66.7-33.3 mol % aluminum chloride-1-ethyl-3-methylimidazolium chloride molten salt at 353 K. The electrochemical reduction of Zr(IV) to Zr(IT) is complicated by the precipitation of ZrCl3; however, solutions of Zr(II) can be prepared by reducing Zr(IV) with Al wire. Al-Zr alloys can be electrodeposited from plating baths containing either Zr(IV) or Zr(II), but for a given concentration and current density, baths containing Zr(IV) lead to Al-Zr alloys with the higher Zr content. This result was traced to the diminutive concentration-dependent diffusion coefficient for Zr(II). It was possible to prepare Al-Zr alloys containing up to similar to17% atomic fraction (atom %) Zr. The structure of these deposits depended on the Zr content. Alloys containing less than 5 atom % Zr could be indexed to a disordered face-centered cubic structure similar to pure At, whereas alloys containing similar to17 atom % Zr were completely amorphous (metallic glass). The chloride pitting potentials of alloys with more than 8 atom % Zr were approximately +0.3 V relative to pure Al. (C) 2004 The Electrochemical Society.