Anticorrosive Performance of New Epoxy-Amine Coatings Based on Zinc Phosphate Tetrahydrate as a Nontoxic Pigment for Carbon Steel in NaCl Medium

Influence of Anticorrosive Pigment, Dry-Film Thickness and Conditioning Time on Protective Properties of Two-Component Epoxy Primer

The main protective properties of two-component epoxy coating are connected by the formation of a barrier of a certain thickness between the material and aggressive, environmentally induced reactants. Anticorrosive pigment is added to the coating in order to improve its protective effects. The conditioning time refers to the time interval required for the achievement of satisfactory cohesion bonds between the coating components, as well as a satisfactory adhesion force between the coating and the base material surface. This paper presents insights obtained after experimental research into the influence of input variables (the content of anticorrosive pigment in the coating, dry-film thickness, and conditioning time) on corrosion resistance. The specimens were kept in the aggressive atmosphere of a salt-spray test chamber within time intervals of 120, 240 and 480 h, where they were cyclically sprayed with a 5% sodium chloride (NaCl) solution, and then examined in laboratory conditions. Such a procedure imitated the aggressive conditions of a service environment. After exposure in the salt-spray test chamber, the specimens were tested to determine the protective properties of the coating and to evaluate damage occurring on the coating, with the purpose of assessing the coating quality in relation to the stated input variables. At all times, when the test samples were exposed to the salt chamber atmosphere, the anti-corrosion pigment content was found to have the greatest influence with the thickness of the dry coating film. The conditioning time was an influential factor to a lesser extent, and only in some observed cases. By analyzing the interactions of the input variables and the results obtained based on mathematical models and reaction surfaces, it was possible to define the most optimal values of the input parameters. For example, after 480 h of exposure in a salt chamber, notch corrosion of 0.6 mm was observed at a dry-film thickness of D1 and an anti-corrosion pigment content of 10%.

Optimization of Parameters for Protection of Materials by Primer Application

The protective properties of coating systems usually depend on their base layer, since its characteristics and chemical composition are greatly responsible for prevention of corrosion development. Moreover, a good primer as a base coating has to provide good adhesion between the coating system and the substrate material, as well as good cohesion, i.e., coating strength. The described experiment aimed to determine the influence of input parameters (anticorrosive pigment content, conditioning time, dry film thickness) on the adhesion properties of the coating. The optimization of input parameters was achieved by the pull-off test in order to determine their maximum values. For the purpose of imitating aggressive atmosphere of service conditions, the experiment was run in a salt spray chamber, in which samples were cyclically sprayed with 5% sodium chloride (NaCl) solution for 120 h. The obtained mathematical model makes it possible to define the optimal values of the input variables for the defined values of the required property, i.e., the adhesion properties of the applied primer for certain exploitative conditions.

Dual Component Polymeric Epoxy-Polyaminoamide Based Zinc Phosphate Anticorrosive Formulation for 15CDV6 Steel

The present research is focused on a formulation with two active components as an anticorrosive polymer coating for 15CDV6 steel. The dual component formulation (epoxy-zinc phosphate (ZP) coating) consists of a polymeric epoxy resin Bisphenol A diglycidyl ether (DGEBA) cured with a polyaminoamide as a first component and zinc phosphate (Zn3(PO4)2(H2O)4) (ZP) added in 5% by weight as a second component. The anticorrosive performance of the epoxy-ZP coating was evaluated against the standard coating, which consists of only one component, the cured polymeric epoxy resin. The two polymer coatings were evaluated by electrochemical impedance spectroscopy (EIS). The surface morphology was of the two polymer coatings were characterized by scanning electron microscopy (SEM). The coated samples of 15CDV6 steel were tested in a harsh environment of corrosive electrolytes (3 wt % NaCl solution). Under these conditions, a very high impedance value was obtained for 15CDV6 steel coated with the epoxy-ZP coating. Even after exposure for a long period of time (5856 h), the performance was still acceptable, indicating that the epoxy-ZP coating is an excellent barrier. The standard epoxy coating provided an adequate corrosion protection performance for a short period of time, then the performance started to decline. The results were confirmed by surface characterization, a cross-sectional image obtained by optical microscopy for an epoxy-ZP coating applied on 15CDV6 steel exposed for 5856 h to a salt spray test showed that the coating is homogeneous and adheres well to the surface of the steel. So, the coating with a dual component could have great potential in marine applications as anticorrosive for steel.

Rheological, electrochemical, surface, DFT and molecular dynamics simulation studies on the anticorrosive properties of new epoxy monomer compound for steel in 1 M HCl solution

A new epoxy monomer, namely, tetraglycidyl-1,2-aminobenzamide (ER), was synthesized by condensation of the amines with epichlorohydrin in a basic medium. The obtained epoxy monomer was characterized by FT-IR and ¹H NMR spectroscopy. Rheological properties of this monomer were determined using an advanced rheometer. Subsequently, the synthesized ER monomer was investigated as corrosion inhibitor for carbon steel in 1 M HCl solution. The adsorption properties of ER were analyzed by electrochemical, surface investigation and theoretical computational studies using DFT and molecular dynamics (MD). Results showed a high dependence of the viscosity of ER on temperature and concentration, and also, that ER has better inhibition performance. A good agreement between the results derived from computational (MD and DFT) and experimental methods was observed. The thermodynamic parameters, along with the kinetic parameters, showed that the adsorption of ER molecules onto carbon steel surface obeyed the Langmuir isotherm model, and the adsorption at metal–electrolyte interfaces involved both chemical and physical adsorption, but predominantly chemisorption mechanism.

A new epoxy monomer, namely, tetraglycidyl-1,2-aminobenzamide (ER), was synthesized by condensation of the amines with epichlorohydrin in a basic medium.

Adsorption and anticorrosive behavior of aromatic epoxy monomers on carbon steel corrosion in acidic solution: computational studies and sustained experimental studies

Herein, the synthesis, characterization and corrosion inhibition effectiveness of two aromatic epoxy monomers (AEMs) namely, 2-(oxiran-2-yl-methoxy)-N,N-bis(oxiran-2-yl-methyl)aniline (AEM1) and N,N-bis(oxiran-2-ylmethyl)-2-((oxiran-2-ylmethyl) thio)aniline (AEM2), in carbon steel corrosive dissolution in 1 M HCl solution is investigated using computational and experimental techniques. AEM1 and AEM2 were characterized using FT-IR, ¹H NMR and ¹³C NMR spectroscopy techniques. Electrochemical results demonstrated that AEMs act as reasonably good corrosion inhibitors for carbon steel in 1 M HCl medium and their effectiveness followed the sequence: AEM2 (95.4%) > AEM1 (94.3%). A PDP study showed that AEMs act as mixed-type inhibitors with slight anodic predominance. Adsorption of the AEMs obeyed the Langmuir isotherm model. Interactions between AEMs and the metallic surface was further studied using DFT and MD simulations that give several computational parameters such as I, A, E_HOMO, E_LUMO, ΔE, δ, χ, ρ, σ, η, ΔN and E_ads. The experimental and computational results were in good agreement and well complimented each other.

Herein, the synthesis, characterization and corrosion inhibition effectiveness of two aromatic epoxy monomers (AEMs) in carbon steel corrosive dissolution in 1 M HCl solution was investigated using computational and experimental techniques.