Water resistant reactive microcapsules for self-healing coatings in harsh environments

Developments in anticorrosive organic coatings modulated by nano/microcontainers with porous matrices

The durability and functionality of many metallic structures are seriously threatened by corrosion, which makes the development of anticorrosive coatings imperative. This state-of-the-art survey explores the recent developments in the field of anticorrosive organic coatings modulated by innovations involving nano/microcontainers with porous matrices. The integration of these cutting-edge delivery systems seeks to improve the protective properties of coatings by enabling controlled release, extended durability, targeted application of corrosion inhibitors, and can be co-constructed to achieve defect filling by polymeric materials. The major highlight of this review is an in-depth analysis of the functionalities provided by porous nano/microcontainers in the active protection and self-healing of anticorrosive coatings, including their performance evaluation. In one case, after 20 days of immersion in 0.1 M NaCl, a scratched coating containing mesoporous silica nanoparticles loaded with an inhibitor benzotriazole and shelled with polydopamine (MSNs-BTA@PDA) exhibited coating restoration indicated by a sustained corrosion resistance rise over an extended period monitored by impedance values at 0.01 Hz frequency, rising from 8.3 × 104 to 7.0 × 105 Ω cm2, a trend assigned to active protection by the release of inhibitors and self-healing capabilities. Additionally, some functions related to anti-fouling and heat preservation by nano/microcontainers are highlighted. Based on the literature survey, some desirable properties, current challenges, and prospects of anticorrosive coatings doped with nano/microcontainers have been summarized. The knowledge gained from this survey will shape future research directions and applications in a variety of industrial areas, in addition to advancing smart corrosion prevention technology.

Multilayered LDH/Microcapsule Smart Epoxy Coating for Corrosion Protection

A multilayered smart epoxy coating for corrosion prevention of carbon steel was developed and characterized. Toward this direction, as a first step, zinc-aluminum nitrate-layered double hydroxide (Zn/Al LDH) was synthesized using the hydrothermal crystallization technique and then loaded with dodecylamine (DOD), which was used as an inhibitor (pH-sensitive). Similarly, the synthesis of the urea-formaldehyde microcapsules (UFMCs) has been carried out using the in-situ polymerization method, and then the microcapsules (LAUFCs) were encapsulated with linalyl acetate (LA) as a self-healing agent. Finally, the loaded Zn/Al LDH (3 wt %) and modified LAUFCs (5 wt %) were reinforced into an epoxy matrix to develop a double-layer coating (DL-EP). For an exact comparison, pre-layer epoxy coatings comprising 3 wt % of the loaded Zn/Al LDH (referred to as LDH-EP), top-layer epoxy coatings comprising 5 wt % linalyl acetate urea-formaldehyde microcapsules (referred to as UFMLA COAT), and a blank epoxy coating (reference coating) were also developed. The developed epoxy coatings were characterized using various techniques such as XRD, XPS, BET, TGA, FTIR, EIS, etc. Electrochemical tests performed on the synthesized coatings indicate that the DL-EP demonstrates improved self-healing properties compared to LDH-EP and UFMLA COAT.

A Comparative Study on the Self-Healing Characterizations and Formulation Optimization of Polyurea Coating

Self-healing materials, especially self-healing polyurea/polyurethane, to replace traditional coating has been of increasing interest in the past decade. The frequency of regular maintenance work can also be reduced as the coating is capable of forming bonds at ruptured sites. This reduces the cost of maintenance and the risk involved in workers engaging in maintenance work. The extremely short curing time of polyurea coating could potentially outweigh the cost due to its short down time. With a high self-healing efficiency, self-healing polyurea could be the ultimate choice of protective coating. This report aims to find the optimum formulation for fabrication of polyurea with a high self-healing efficiency. This is conducted by changing the composition of the components chosen for formulation of polyurea. The choice of isocyanate and amine is varied to explore its impact on chain mobility and microphase separation, which are important factors affecting self-healing efficiency. A series of characterizations, including ATR-FTIR, DSC, optical microscope and mechanical tester, is used to analyze the factors affecting the self-healing efficiency of fabricated polyurea and to eventually determine the best formulation. The ideal formulation of toluene 2,4 diisocyanate-amine (TDI-P1000) polyurea managed to achieve a self-healing of 42%. Further studies could be done to include multiple healing mechanisms after different area of polyurea to boost its self-healing efficiency after repeated healing.

Mini-Review of Self-Healing Mechanism and Formulation Optimization of Polyurea Coating

Self-healing polymers are categorized as smart materials that are capable of surface protection and prevention of structural failure. Polyurethane/polyurea, as one of the representative coatings, has also attracted attention for industrial applications. Compared with polyurethane, polyurea coating, with a similar formation process, provides higher tensile strength and requires shorter curing time. In this paper, extrinsic and intrinsic mechanisms are reviewed to address the efficiency of the self-healing process. Moreover, formulation optimization and strategic improvement to ensure self-healing within a shorter period of time with acceptable recovery of mechanical strength are also discussed. The choice and ratio of diisocyanates, as well as the choice of chain extender, are believed to have a crucial effect on the acceleration of the self-healing process and enhance self-healing efficiency during the preparation of polyurea coatings.

Self-Healing Performance of Smart Polymeric Coatings Modified with Tung Oil and Linalyl Acetate

This work focuses on the synthesis and characterization of polymeric smart self-healing coatings. A comparison of structural, thermal, and self-healing properties of two different polymeric coatings comprising distinct self-healing agents (tung oil and linalyl acetate) is studied to elucidate the role of self-healing agents in corrosion protection. Towards this direction, urea-formaldehyde microcapsules (UFMCs) loaded with tung oil (TMMCs) and linalyl acetate (LMMCs) were synthesized using the in-situ polymerization method. The synthesis of both LMMCs and TMMCs under identical experimental conditions (900 rpm, 55 °C) has resulted in a similar average particle size range (63-125 µm). The polymeric smart self-healing coatings were developed by reinforcing a polymeric matrix separately with a fixed amount of LMMCs (3 wt.% and 5 wt.%), and TMMCs (3 wt.% and 5 wt.%) referred to as LMCOATs and TMCOATs, respectively. The development of smart coatings (LMCOATs and TMCOATs) contributes to achieving decent thermal stability up to 450 °C. Electrochemical impedance spectroscopy (EIS) analysis indicates that the corrosion resistance of smart coatings increases with increasing concentration of the microcapsules (TMMCs, LMMCs) in the epoxy matrix reaching ~1 GΩ. As a comparison, LMCOATs containing 5 wt.% LMMCs demonstrate the best stability in the barrier properties than other developed coatings and can be considered for many potential applications.

Microencapsulation of reactive isocyanates for application in self-healing materials: a review

Microencapsulation of curing agents is a major strategy for the development of self-healing polymers. Isocyanates are among the most promising compounds for the development of one-part, catalyst free, self-healing materials, but their microencapsulation is challenging due to their high reactivity. To keep the healing agent intact in the liquid state and containing free-NCO groups, the monitoring of several synthesis parameters is essential. This review aims to summarise the outcomes in the microencapsulation of isocyanates, emphasising the efforts reported in the literature to modulate the microcapsule properties. In this regard, the main synthesis procedures are presented, followed by the most relevant characterisation methods used to assess microcapsule properties. The correlation between these properties and synthesis parameters is also discussed, and finally the main potential and challenges for industrial applications are highlighted.

Preparation and Performance of a Waterborne UV/Al Low Infrared Emissivity Coating

An Al powder filler, nano silica slurry and KH560 were mixed with a prepared waterborne UV-curable coating, and the coating was optimized by an orthogonal experiment. Influences of the Al powder concentration on the gloss, infrared emissivity, brightness, mechanical properties, corrosion resistance and other related properties of the coating were further discussed. The results show that the influence of the Al powder concentration on the gloss was more significant, followed by the UV curing time and nano silica slurry concentration. After studying the key role of the concentration of the Al powder, we found that as the concentration of the Al powder is augmented from 10.0% to 25.0%, the gloss lessened from 19.1% to 8.5%. As the concentration of the Al powder was augmented from 10.0% to 40.0%, the infrared emissivity lessened from 0.649 to 0.083 and the brightness L’ value of the coating was step-by-step augmented and inclined to be stable; in addition, the coating’s mechanical properties reached an excellent level. The coating containing 25.0% Al powder had the best corrosion resistance, surface morphology and comprehensive properties, which can potentially be used for infrared stealth technology.

A Facile Strategy To Prepare Smart Coatings with Autonomous Self-Healing and Self-Reporting Functions

Herein, we report a smart coating with autonomous self-healing and self-reporting functions by simple integration of one-component microcapsules into the matrix without external intervention. The microcapsules containing hexamethylene diisocyanate (HDI) solution of aggregation-induced emission luminogens (AIEgens) were synthesized, and their properties, such as their composition, thermal stability, morphology, and damage-indicating ability, were investigated systematically. The AIEgen/HDI microcapsule-embedded coatings display adaptive self-repair of scratches and simultaneous high-contrast indication of the healed damage. Two commercialized AIEgens, tetraphenylethylene (TPE) and its derivative with dimethoxyl and benzylidene-methyloxazolone moieties (DM-TPE-BMO), were utilized as examples to demonstrate the feasibility of this concept in diverse polymer matrixes (including blue autofluorescent matrixes). It was found that the content of AIEgens can even be lowered to 0.05 wt %. This facile, economical, and feasible strategy toward the dual functions of self-repairing and self-sensing provides a new route for enhancing the longevity and reliability of polymer coatings, which is appealing and of great importance in practical applications.

Self-Repairing Composites for Corrosion Protection: A Review on Recent Strategies and Evaluation Methods

The use of self-healing coatings to protect metal substrates, such as aluminum alloys, stainless steel, carbon steel, and Mg alloys from corrosion is an important aspect for protecting metals and for the economy. During the past decade, extensive transformations on self-healing strategies were introduced in protective coatings, including the use of green components. Scientists used extracts of henna leaves, aloe vera, tobacco, etc. as corrosion inhibitors, and cellulose nanofibers, hallyosite nanotubes, etc. as healing agent containers. This review gives a concise description on the need for self-healing protective coatings for metal parts, the latest extrinsic self-healing strategies, and the techniques used to follow-up the self-healing process to control the corrosion of metal substrates. Common techniques, such as accelerated salt immersion test and electrochemical impedance spectroscopy (EIS), for evaluating the self-healing process in protective coatings are explained. We also show recent advancements procedures, such as scanning vibrating electrode technique (SVET) and scanning electrochemical microscopy (SECM), as successful techniques in evaluating the self-healing process in protective coatings.

Preparation and Characterization of Urea Formaldehyde @ Epoxy Resin Microcapsule on Waterborne Wood Coatings

Urea formaldehyde @ epoxy resin microcapsules were prepared by two steps in situ polymerization, and the morphology and composition of microcapsules with different mass ratios of core to wall material were examined by scanning electron microscopy (SEM) and infrared (IR) spectroscopy. The microcapsules were added to the waterborne wood coatings to explore the effect of microcapsules on the properties of coatings and their self-repairing characteristics, and the gloss, hardness, adhesion, and impact resistance of the waterborne wood coatings were investigated. The results showed that when the concentration of microcapsule was 10.0% and the mass ratio of core to wall material was 0.83:1, the waterborne wood coatings had a good comprehensive performance and less negative impact. In the scratch test, the waterborne wood coatings with a concentration of 10.0% microcapsule had good repair ability. The possibility of applying the self-repairing technology of microcapsule to waterborne wood coatings was discussed through the preparation and performance characterization of self-repairing coatings and the results can become a guideline for the engineering application of waterborne wood coatings.

Synthesis of calcium carbonate microcapsules as self-healing containers

Contemporary studies of self-healing polymer composites are based on microcapsules synthesized using synthetic and toxic polymers, biopolymers, etc. via methods such as in situ polymerization, electrospraying, and air atomization. Herein, we synthesized a healing agent, epoxy (EPX) encapsulated calcium carbonate (CC) microcapsules, which was used to prepare self-healing EPX composites as a protective coating for metals. The CC microcapsules were synthesized using two facile methods, namely, the soft-template method (STM) and the in situ emulsion method (EM). Microcapsules prepared using the STM (ST-CC) were synthesized using sodium dodecyl sulphate (SDS) surfactant micelles as the soft-template, while the microcapsules prepared using the EM (EM-CC) were synthesized in an oil-in-water (O/W) in situ emulsion. These prepared CC microcapsules were characterized using light microscopy (LMC), field emission scanning electron microscopy (FE-SEM), fourier transform infrared spectroscopy (FTIR), nuclear magnetic resonance spectroscopy (NMR), and thermogravimetric analysis (TGA). The synthesized ST-CC microcapsules were spherical in shape, with an average diameter of 2.5 μm and an average shell wall thickness of 650 nm, while EM-CC microcapsules had a near-spherical shape with an average diameter of 3.4 μm and an average shell wall thickness of 880 nm. The ST-CC capsules exhibited flake-like rough surfaces while EM-CC capsules showed smooth bulgy surfaces. The loading capacity of ST-CC and EM-CC microcapsules were estimated using TGA and found to be 11% and 36%, respectively. The FTIR and NMR spectra confirmed the EPX encapsulation and the unreactive nature of the loaded EPX with the inner walls of CC microcapsules. The synthesized CC microcapsules were further incorporated into an EPX matrix to prepare composite coatings with 10 (w/w%), 20 (w/w%), and 50 (w/w%) capsule loadings. The prepared EPX composite coatings were scratched and observed using FE-SEM and LMC to evaluate the release of encapsulated EPX inside the CC capsules, which is analogous to the healing behaviour. Moreover, EPX composite coatings with 20 (w/w%) and 50 (w/w%) of ST-CC showed better healing performances. Thus, it was observed that ST-CC microcapsules outperformed EM-CC. Additionally, the EPX/CC coatings showed remarkable self-healing properties by closing the gaps of the scratch surfaces. Thus, these formaldehyde-free, biocompatible, biodegradable, and non-toxic CC based EPX composite coatings hold great potential to be used as a protective coating for metal substrates. Primary results detected significant corrosion retardancy due to the self-healing coatings under an accelerated corrosion process, which was performed with a salt spray test.

Healing agent, epoxy encapsulated calcium carbonate microcapsules were prepared using a facile method as a self-healing composite for protective metal coatings.

Novel Dual-Component Microencapsulated Hydrophobic Amine and Microencapsulated Isocyanate Used for Self-Healing Anti-Corrosion Coating

Dual component microencapsulated hydrophobic amine and microencapsulated isocyanate were designed and fabricated for self-healing anti-corrosion coating. In this system, novel hydrophobic polyaspartic acid ester (PAE) and isophorone diisocyanate (IPDI) were microencapsulated respectively with melamine-formaldehyde (MF) as shell via in situ polymerization. To reduce the reaction activity between shell-forming MF prepolymer and PAE, another self-healing agent tung oil (TO) was dissolved in PAE and subsequently employed as core material. With field-emission scanning electron microscopy (FE-SEM) and optical microscopy (OM), the resultant microencapsulated IPDI with diameter of 2⁻5 μm showed a spherical shape and smooth surface. More importantly, both the morphology and microstructure of microencapsulated PAE enhanced significantly after addition of TO. Fourier transform infrared spectra (FTIR) analysis confirmed the molecular structure of chemical structure of the microcapsules. Thermal gravimetric analysis (TGA) indicated that both kinds of microcapsules exhibit excellent thermal resistance with the protection of MF shell. Furthermore, the self-healing epoxy coating system containing microencapsulated IPDI and microencapsulated PAE/TO was prepared and investigated. From the micrographs of true color confocal microscope (TCCM), the self-healing coating containing dual-component microcapsules showed excellent self-repairing performance compared to single microencapsulated IPDI system, and the optimal content of dual-component microcapsules in epoxy coating was 20 wt % approximately.

Electrospray biodegradable microcapsules loaded with curcumin for drug delivery systems with high bioactivity

Biodegradable microcapsules as novel drug delivery systems were successfully fabricated by one-step processing using an electrospray technique.

Microencapsulation: an emerging technique in the modern coating industry

The protection of metal from corrosion is of great interest for which various methods have been implemented in the past such as organic–inorganic protective coatings, use of corrosion inhibitors, sol–gel coatings, self healing coatingsetc.