Water diffusion with temperature enabling predictions for sorption and transport behavior in thermoset materials

A Self-Healing Thermoset Epoxy Modulated by Dynamic Boronic Ester for Powder Coating

Thermoset powder coatings exhibit distinctive characteristics such as remarkable hardness and exceptional resistance to corrosion. In contrast to conventional paints, powder coatings are environmentally friendly due to the absence of volatile organic compounds (VOCs). However, their irreversible cross-linking structures limit their chain segment mobility, preventing polymers from autonomously repairing cracks. Dynamic cross-linking networks have garnered attention for their remarkable self-healing capabilities, facilitated by rapid internal bond exchange. Herein, we introduce an innovative method for synthesizing thermoset epoxy containing boronic ester moieties which could prolong the life of the powder coating. The epoxy resin system relies on the incorporation of two curing agents: one featuring small-molecule diamines with boronic bonds and the other a modified polyurethane prepolymer. A state of equilibrium in mechanical properties was achieved via precise manipulation of the proportions of these agents, with the epoxy composite exhibiting a fracture stress of 67.95 MPa while maintaining a stable glass transition temperature (Tg) of 51.39 °C. This imparts remarkable self-healing ability to the coating surface, capable of returning to its original state even after undergoing 1000 cycles of rubbing (using 1200-grit abrasive paper). Furthermore, the introduction of carbon nanotube nanoparticles enabled non-contact sequential self-healing. Subsequently, we introduce this method into powder coatings of different materials. Therefore, this work provides a strategy to develop functional interior decoration and ensure its potential for broad-ranging applications, such as aerospace, transportation, and other fields.

Water Uptake in Epoxy Ionic Liquid Free Film Polymer by Gravimetric Analysis and Comparison with Nondestructive Dielectric Analysis

Due to their high surface coverage, good adhesion to metal surfaces, and their excellent corrosion resistance, epoxy thermosets are widely used as protective coatings. However, anticorrosion protection of these coatings can be improved against water uptake and can be tuned by changing the chemical nature of the curing agents. In this work, a comparative study has been performed on the water uptake of an epoxy-amine based on bisphenol A diglycidyl ether (DGEBA) cured with an aliphatic amine and the same epoxy initiated with a phosphonium ionic liquid (IL). Thus, the epoxy networks were immersed in saline water solution in a controlled temperature environment. Gravimetric and electric impedance measurements were carried out for a maximum of 3 months. Results were analyzed in order to assess the water diffusion coefficients and water saturation limits. Two models, the Brasher-Kingsbury and a novel mixing rule, were applied on permittivity values. Results highlighted that epoxy-ionic liquid systems are less sensitive to water uptake than conventional epoxy-amine networks. Due to their higher hydrophobic properties the water diffusion coefficient of epoxy-ionic liquid systems are two times less compared to epoxy-amine samples and the water saturation limit is more than four times less. The analysis also shows that the novel mixing rule model proposed here is prone to better estimate the water uptake with accuracy from electrical impedance measurements.

A Critical Review of the Time-Dependent Performance of Polymeric Pipeline Coatings: Focus on Hydration of Epoxy-Based Coatings

The barrier performance of organic coatings is a direct function of mass transport and long-term stability of the polymeric structure. A predictive assessment of the protective coating cannot be conducted a priori of degradation effects on transport. Epoxy-based powder coatings are an attractive class of coatings for pipelines and other structures because application processing times are low and residual stresses between polymer layers are reduced. However, water ingress into the polymeric network of these coatings is of particular interest due to associated competitive sorption and plasticization effects. This review examines common analytical techniques for identifying parameters involved in transport in wet environments and underscores the gaps in the literature for the evaluation of the long-term performance of such coating systems. Studies have shown that the extent of polymer hydration has a major impact on gas and ion permeability/selectivity. Thus, transport analyses based only on micropore filling (i.e., adsorption) by water molecules are inadequate. Combinatorial entropy of the glassy epoxy and water vapor mixture not only affects the mechanism of membrane plasticization, but also changes the sorption kinetics of gas permeation and causes a partial gas immobility in the system. However, diffusivity, defined as the product of a kinetic mobility parameter and a concentration-dependent thermodynamic parameter, can eventually become favorable for gas transport at elevated temperatures, meaning that increasing gas pressure can decrease selectivity of the membrane for gas permeation. On the other hand, reverse osmosis membranes have shown that salt permeation is sensitive to, among other variables, water content in the polymer and a fundamental attribute in ionic diffusion is the effective size of hydrated ions. In addition, external electron sources-e.g., cathodic protection potentials for pipeline structures-can alter the kinetics of this transport as the tendency of ions to dissociate increases due to electrostatic forces. Focusing primarily on epoxy-based powder coatings, this review demonstrates that service parameters such as humidity, temperature, and concentration of aggressive species can dynamically develop different transport mechanisms, each at the expense of others. Although multilayered coating systems decrease moisture ingress and the consequences of environmental exposure, this survey shows that demands for extreme operating conditions can pose new challenges for coating materials and sparse data on transport properties would limit analysis of the remaining life of the system. This knowledge gap impedes the prediction of the likelihood of coating and, consequently, infrastructure failures.

Study on diffusion mechanism and failure behavior of epoxy coatings focusing on synergistic effect of temperature and water molecules

The research on the diffusion of water in coatings has been a hot topic in many fields, such as chemistry, coating structure and hydrogen bonding. In this paper, DGEBA epoxy coating was used as a sample to explore the diffusion process of 3 wt.% NaCl solution at different temperatures. Two-stage diffusion was established by immersion experiment and MD simulation. The synergistic effect of temperature and water on DGEBA properties was revealed by FTIR method and adsorption-desorption cyclic testing. The results showed that as the temperature increased, the saturation water content in coatings increased. At different temperatures, the diffusion process of water presented two-phase characteristics, and the influence of temperature on the diffusion process was mainly manifested in the cross-linking density at higher locations. Based on the variation law of swelling coefficient in per unit time (24 h), the conditions for water-coating interaction and formation of water clusters in this paper were proposed. The synergistic effect of water and temperature on DGEBA properties was reflected in two aspects: at lower temperature (20 °C), water would only change the physical structure of the coatings, while the water broke the DGEBA chains at higher temperature (60 °C).

A Comprehensive Review on Water Diffusion in Polymers Focusing on the Polymer-Metal Interface Combination

Water diffusion in polymers is relevant to a broad range of physicochemical phenomena and technological processes. Although many fields contributed to rapid progress in the fundamental knowledge of water-polymer interactions, detailed understandings come mainly from interpreting numerous experiments. These studies showed that a remarkably rich variety of diffusion forms between water and even seemingly simple polymers. In this review, focusing on the gravimetric and capacitance method, we discuss contradictions and problems existing for water diffusion in polymers in detail from perspectives of experiments and models, focusing on the analysis of error derived from widely used methods, especially for the Brasher-Kingsbury equation. We also provide a perspective on outstanding problems, challenges, and open questions, including water clusters, relaxation, and electrochemical reactions at the metal/polymer interface, as well as expanding the theoretical prospective.

Unraveling the Mechanistic Origins of Epoxy Degradation in Acids

Water diffusion into polymers like thermosetting epoxies is well-studied; however, comparably little has been reported thus far on the related but very different mechanism of acid diffusion and the corresponding influence on material degradation. The diffusion of hydrochloric acid into an amine-cured epoxy system was studied in this work using gravimetric analysis and dielectric monitoring concurrently, and the mass uptake behavior was observed to differ significantly compared with water diffusion, faster by an order of magnitude. A unique 3-stage diffusion of acid into epoxy was observed due to the influence of Coulombic interactions between oppositely charged ionic species diffusing at different rates. Material characterization studies have revealed that the dominant degradation mechanism is physical in nature, with the formation of surface cracks driven by the swelling stresses due to the core-shell swelling behavior in highly concentrated hydrochloric acid, leading to an erosion-type degradation phenomenon. The insights gained from understanding acid electrolyte diffusion could serve to design a more effective and efficient process to enable thermoset recycling by facilitating rapid material breakdown or the design of acid-resistant materials for various applications in chemical storage tanks, batteries, and protective coatings in a corrosive environment.