Mechanism Insights in Anticorrosion Performance of Waterborne Epoxy Coatings Reinforced by PEI-Functionalized Boron Nitride Nanosheets

Functionalized hexagonal boron nitride nanosheets (BNNSs) have arisen as compelling anticorrosive additives, yet the precise mechanism of their corrosion resistance enhancement in coatings remains unclear. Here, polyethylenimine functionalized BNNSs (PEI-BNNSs) with approximately 6-11 layers were prepared through a "one-step" method. Then, the PEI-BNNSs/Waterborne epoxy (WEP) composite coatings were incorporated via the waterborne latex blending method for the anticorrosion of the Q235 substrate. The impedance modulus (|Z|f = 0.01 Hz) of 0.5 wt % PEI-BNNSs/WEP composite coating soaked in 3.5 wt % NaCl solution for 35 days increased by 4 orders of magnitude compared to pure WEP coating, exhibiting exceptional long-term resistance against corrosion. The positron annihilation lifetime spectroscopy and corrosion product analysis demonstrated that the reinforced anticorrosion capabilities are not solely ascribed to the "tortuous path effect" arising from BNNSs impermeability. These mechanisms also encompass the reduction in free volume fraction and radius of the free volume cavities within the composite coating brought about by the PEI molecules. Additionally, the increase in coating adhesion, promoted by PEI, plays an important role in augmenting the barrier properties against corrosive agents. This study provided a full comprehension of the role played by functionalized BNNSs in fortifying the anticorrosion attributes of WEP coatings.

Ab initio study of the vibrational spectra of amorphous boron nitride

Boron Nitride (BN) is an interesting polymorphic insulator that is commonly found in four different crystalline structures, each one with different electrical and mechanical properties which makes it an attractive material for technological and industrial applications. Seeking to improve its features, several experimental and simulational works have studied the amorphous phase (a-BN) focusing on electronic and structural properties, pressure-induced phase transformations, and a hydrogenated form of a-BN. By means of ab initio Molecular Dynamics and our well-proven amorphization process known as the undermelt-quench approach, herein three amorphous supercells were computationally generated, two with 216 atoms (densities of 2.04 and 2.80 g cm-3) and a third one with 254 atoms (density of 3.48 g cm-3). The topology, the vibrational density of states and some thermodynamic properties of the three samples are reported and compared with existing experiments and with other computational results.

Bio-inspired Ti3C2Tx MXene composite coating for enhancing corrosion resistance of aluminum alloy in acidic environments

Aluminum alloy (Al alloy) suffers from severe corrosion in acidic solution. Two-dimensional (2D) MXene-based composite coatings show great prospects for corrosion protection on metals used in special conditions. The composite coatings still face challenges in complex functionalization and orientation control. In harsh conditions, the long-term ability and roles of MXene in corrosion protection are still not clear. Here, a bio-inspired myristic-calcium chloride-Ti3C2Tx MXene (MA + CaCl2 + MXene) composite coating is successfully prepared on aluminum alloy (Al alloy) by electrodeposition process. Electrochemical tests, surface morphology, and chemical composition are analyzed to investigate the corrosion resistance and protection mechanism of the MXene coating in acidic solution (0.5 M H2SO4 + 2 ppm HF). As a result, the incorporation of MXene can significantly reduce corrosion current density (7.498 × 10-8 A/cm2) by ∼ 5 orders of magnitude and impedance modulus at 0.01 Hz (|Z|0.01 Hz) value of the composite coating is 196.8 Ω·cm2, which is over 4 times higher than that of bare Al alloy (40.74 Ω·cm2) after immersion test for 72 h. Furthermore, the in-situ corrosion test confirms the enhanced corrosion resistance of the MA + CaCl2 + MXene composite coating. The MXene can increase coating thickness to 23.6 ± 0.4 μm, reduce porosity to (5.845 ± 1) × 10-5, decrease the diffusion coefficients of H+ to (1.587 ± 0.3) × 10-9 cm2/s, and enhance the adhesion of the coating to the substrate (the delamination time exceeds 5 h), thus providing improved anti-corrosion ability. This strategy opens up new prospects for construction of 2D MXene-based anti-corrosion coatings.

2D hexagonal boron nitride (h-BN) nanosheets in protective coatings: A literature review

The layered 2D hexagonal boron nitride (h-BN) nanosheets (BNNSs) have received significant attention as effective fillers for composite protective coatings in anti-corrosion, anti-oxidation and anti-wear applications. Vapour deposited h-BN mono/multilayers are related classes well-recognized as protective thin films and coatings. This review comprehensively accounts for the research and development of BNNSs in protective coatings. Chemical vapour deposited (CVD) BN thin films and exfoliated BNNSs-incorporated composite polymer coatings are primarily discussed. Inorganic and nanocarbon-based composite coatings are also covered. Future research potentials are presented.

Emerging Layered Materials and Their Applications in the Corrosion Protection of Metals and Alloys

Metals and alloys are essential in modern society, and are used in our daily activities. However, they are prone to corrosion, with the conversion of the metal/alloy to its more thermodynamically-favored oxide/hydroxide phase. These undesirable corrosion reactions can lead to the failure of metallic components. Consequently, corrosion-protective technologies are now more important than ever, as it is essential to reduce the waste of valuable resources. In this review, we consider the role of emerging 2D materials and layered materials in the development of a corrosion protection strategy. In particular, we focus on the materials beyond graphene, and consider the role of transition metal dichalcogenides, such as MoS2, MXenes, layered double hydroxides, hexagonal boron nitride and graphitic carbon nitride in the formulation of effective and protective films and coatings. Following a short introduction to the synthesis and exfoliation of the layered materials, their role in corrosion protection is described and discussed. Finally, we discuss the future applications of these 2D materials in corrosion protection.

Bio-inspired Multifunctional Graphene-Epoxy Anticorrosion Coatings by Low-Defect Engineered Graphene

Although graphene has been regarded as the most ideal anticorrosion filler, to date, some vital problems including poor dispersion, disordered arrangement, structure defects, and galvanic corrosion remain unresolved,, thus blocking its potential application in metal protection. In this work, a bio-inspried multilayered graphene-epoxy composite coating was fabricated through a scalable spraying approach with well-dispersed low-defect engineered graphene as the functional filler. Polydopamine served as an enforcer to improve the dispersity and repair the structure defects of graphene (π-π interaction) and bridged the dense graphene layers and epoxy layers (strong adhesion) for forming "interlock" structures to ensure complete coating systems. Electrochemical tests confirmed that the bio-inspired composite coating showed elevated coating resistance from 4.2 × 10⁶ Ω cm² for blank coating and 2.5 × 10⁸ Ω cm² for blending composite coating to 3.0 × 10⁹ Ω cm². The highly anisotropic graphene layers endowed the bio-inspried coating with highly anisotropic thermal and electrical conductivities, with the in-plane and through-plane thermal conductivities being 0.78 and 0.21 W/mK, respectively. Besides, the good anisotropic conductivities make the bio-inspired coating achieve self-monitoring of structural safety and health. This bio-inspired strategy provides a fascinating method for constructing high-performance graphene composite coatings with functional properties.

Taking Advantage of Phosphate Functionalized Waterborne Acrylic Binders to Get Rid of Inhibitors in Direct-to-Metal Paints

In this paper, two phosphate functionalized acrylic binders are formulated to yield direct-to-metal paints without using corrosion inhibitors. The difference between both binders is the addition of polystearylacrylate crystalline nanodomains in one of them, and an amorphous methyl methacylate-co-butyl acrylate copolymer in the other. The water sensitivity, mechanical stability, adhesion, and the performance of the paints against corrosion (high humidity resistance, accelerated weathering, and salt-spray tests) are assessed and compared with a DTM paint formulated from a commercial binder. The performance of both phosphate functionalized paints formulated without corrosion inhibitors in high humidity and weathering tests is superior to the commercial DTM paint formulated without corrosion inhibitors and similar to the DTM paint formulated with them. Furthermore, the paint based on the amorphous copolymer binder provides significantly good performance in the salt spray test (even superior to that of the DTM paint formulated with corrosion inhibitors).

High-yield preparation of edge-functionalized and water dispersible few-layers of hexagonal boron nitride (hBN) by direct wet chemical exfoliation

Owing to many fascinating properties including high thermal and chemical stability, excellent electrical insulation, fire-retardant and antibacterial properties, hexagonal boron nitride (hBN) has emerged as a prominent 2D material for broad applications. However, the production of high quality of hBN by chemical exfoliation from its precursor is still challenging. This paper presents a high-yield (+83%), low-cost and energy-efficient wet chemical exfoliation strategy, which produces few-layers (FL, 3-6 layers) of edge-functionalized (OH) hBN nanosheets with uniform size (486 ± 51 nm). This optimized preparation is established based on a comprehensive investigation on the key exfoliation parameters such as exfoliation temperature, time and amount of the oxidant (potassium permanganate). High quality of FL-hBN was confirmed by various characterization techniques including scanning electron microscopy coupled with energy dispersive X-ray, transmission electron microscopy, Raman, Fourier transform infrared spectroscopy, X-ray diffraction and X-ray photoelectron spectroscopy analyses. The outcome of this study paves a promising pathway to effectively produce hBN through a cost-efficient exfoliation approach, which has a significant impact on industrial applications.

Superior to graphene: super-anticorrosive natural mica nanosheets

Graphene has been generally considered to be the most ideal anticorrosive material based on its extraordinary impermeability, but tends in practical applications to promote metal corrosion because of its inherently high electrical conductivity. Mica nanosheets (MNSs), in contrast, display excellent electrical insulation properties, as well as excellent temperature stability and chemical durability, and show tremendous potential for protecting metals, and hence are a promising substitute for graphene. To date, however, there have been no reports about MNS-based anticorrosive coatings, since it is much more difficult to exfoliate high-quality MNSs than other layered materials. In this work, high-concentration (4.3 mg ml-1) ultrathin MNS (1-5 layers) dispersions were synthesized based on a facile and efficient hydrothermal exfoliation approach. Epoxy (EP) coatings were filled with the as-obtained MNSs to enhance the anticorrosion performance of the coatings, and their corrosion behaviors were studied systemically through a series of measurements. With the addition of only 0.4 wt% MNSs, the corrosion rate was observed to be reduced 6500 fold, and the coating impedance increased by four orders of magnitude compared with the blank EP coating. We believe that this method opens a novel avenue for developing high-performance anticorrosive coatings to replace graphene materials for metal protection.

Active anti-corrosion of epoxy coating by nitrite ions intercalated MgAl LDH

Layered double hydroxide (LDH) with NO₂^- intercalation was successfully prepared via acidification oscillation and ion exchange. The nano-fillers were incorporated into the resin to prepare anti-corrosion coatings with the thickness of ca. 50 ± 5 μm. The electrochemical and self-repairing properties of the LDH-doped coatings were studied by EIS and LEIS. Results indicated that the addition of LDH loaded with nitrite induced obvious increased in the impedance of coating (from 4.64 × 10⁸ Ω cm² to 2.14 × 10¹⁰ Ω cm²) and improved the anticorrosion performance of the coating. In addition, the localized corrosion of coatings could be largely inhibited, and the released nitrite ions from LDH interlayers exhibited active anticorrosion functions. When LDH nanosheets were added to the coatings, the lamella structures improved the barrier performances of the coatings. At the same time, the excellent ion exchanges ability of LDH could be used as storage stations for chloride ions, and the release of nitrite ions could play an active anti-corrosion role. Both of them cooperated to synergistically improve the anti-corrosion performance of the coating.

A universal strategy for high-yield producing water compatible boron nitride nanosheets

Boron nitride nanosheets (BNNS) have shown great potential in thermal management applications owing to their high thermal conductivity, electrical insulation, and chemical stability.

Bioinspired Smart Anticorrosive Coatings with an Emergency-Response Closing Function

Emergency-response closing (ERC) of diffusion pathways for aggressive species in graphene/epoxy (G/EP) coatings was achieved via terpyridine derivative (TDD)-functionalized graphene oxide (tGO). Under stimulation from corrosion produced ferrous (Fe²⁺) ions, tGO sheets urgently aggregated through complexation reminiscent of leaves closing on a mimosa. Consequently, the coating showed significantly decreased oxygen (ORT) and water vapor transmittance rate (WVTR) changes after immersion in ferrous solution. According to the simulation and electrochemical results, tGO sheets could self-assemble into 3D architectures with Fe²⁺ ions and efficiently protect metals from aggressive species attack. This tGO/EP coating provided an ERC function via self-adaptability with the Fe²⁺ ions to achieve long-term anticorrosion. The application of tGO/EP to the protection of metal components is therefore validated as a fascinating route for the enhancement of anticorrosion efficiency on graphene anticorrosive coatings, with great potential in durable anticorrosive coatings application.

High-Quality Boron Nitride Nanosheets and Their Bioinspired Thermally Conductive Papers

Hexagonal boron nitride has displayed increased potential in heat dissipation applications due to its desirable high thermal conductivity and remarkable thermal stability. However, the large-yield and high-quality preparation of boron nitride nanosheets (BNNSs) has been still an enormous challenge. In present work, we developed a universal exfoliation strategy to synthesize few-layer and defect-free BNNSs, which involved the intercalation of hexafluorosilicates/sodium hydroxide into BN crystals followed by exfoliation through a mild stirring process. The yield and concentration of as-obtained BNNS reached up to 78.5% and 12.78 mg/mL, respectively. More importantly, this method has been proven to exfoliate other layered materials like graphene (G), MoS₂, and WS₂. These as-obtained BNNSs can be directly used for constructing freestanding papers with high thermal conductivities. Typically, the thermal conductivities of the BNNS-G hybrid paper were up to 63.5 W/mK along the in-plane direction and 7.4 W/mK along the through-plane direction. According to the thermal interface materials performance measures, BNNS-G hybrid paper shows great promising applications for heat transfer in integrated circuit packaging.

Novel nitrogen doped carbon dots enhancing the anticorrosive performance of waterborne epoxy coatings

There are lots of research studies reporting the excellent performances of waterborne epoxy resin coatings to reduce environmental VOC levels. However, it has also been manifested that waterborne epoxy resin coatings do not have high corrosion resistance because of being hydrophilic. Herein, we utilized a kind of N doped carbon dot (N-CD) which has high ethanol solubility and low cytotoxicity to enhance the corrosion resistance of waterborne epoxy resin coatings as a nanofiller. The N-CDs were obtained through a solvothermal method by using 4-aminosalicylic acid (ASA) as a precursor. The diameter and height of N-CDs confirmed by scanning probe microscopy and transmission electron microscopy are 3-5 nm. Corrosion resistance performance of the coatings without and with N-CDs is investigated by electrochemical impedance spectroscopy by immersing them in 3.5 wt% NaCl (aq) for 70 days. The results indicate that the composite coatings with 0.5 wt% N-CDs show superior anticorrosive performance due to bond interactions between N-CDs and polymer chains, the defect repairing effect of N-CDs and the formation of compact Fe₂O₃ and Fe₃O₄ passivation layers.

Influence of carbon nanodots encapsulated polycarbazole hybrid on the corrosion inhibition performance of polyurethane nanocomposite coatings

Carbon nanodots encapsulated in a polycarbazole hybrid-dispersed polyurethane nanocomposite coating with new exciting perspectives for high-performance anticorrosive coatings are shown.