Powder and High-Solid Coatings as Anticorrosive Solutions for Marine and Offshore Applications? A Review

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.

pH-Responsive, Thermoset Polymer Coatings for Active Protection against Aluminum Corrosion

This paper describes the synthesis and use of multifunctional methacrylic monomers, which contain basic (amine) functional groups, including an example in which an acid-labile tert-butylcarbamate-protected glycine is used to form a novel methacrylic monomer. The "protected" amino acid-derived functional monomer (BOC-Gly-MA) is copolymerized with an epoxide functional methacrylic monomer (GMA), to deliver novel multifunctional polymers, which are processed into powder coatings and used to study filiform corrosion at the surface of an aluminum substrate. The BOC-Gly-MA-containing copolymers were shown to improve a coating's anticorrosion performance, presenting the lowest average filiform corrosion (FFC) track length, total FFC number, and total corroded surface area (CSA) of the coatings investigated. Further to this, a mode of action for the role of BOC-Gly functional polymers in corrosion protection is proposed, supported by both solution and polymer-aluminum interface studies, delivering new insights into the mode of action of pH-responsive polymer coatings.

Cr-Free Anticorrosive Primers for Marine Propeller Applications

Marine propellers work under severe service conditions, where they commonly suffer from mechanical, electrochemical, and biological corrosion damage. The major mechanical corrosion involves cavitation, erosion, and impingement corrosion. On the other hand, the major electrochemical corrosion involves galvanic corrosion and electrolysis. As a result, consideration of both desired mechanical and electrochemical properties is necessary when designing a marine propeller coating. In this study, a PVB (polyvinyl butyral) and an epoxy coating were formulated without corrosion inhibitors to investigate the desired coating properties for marine propeller applications. The two coatings were compared with a Cr-containing commercial marine propeller coating to investigate the advantages and disadvantages of using PVB and epoxy for marine propeller coatings. It was found that it is desirable for marine propeller coatings to be flexible to avoid cracking and flaking; to be able to withstand high pH in order to resist cathodic disbondment (electrolysis); to have adequate primer-substrate adhesion; and, ideally, to be able to self-heal when the coating is damaged (cavitation). It was found that the PVB-ZO coating has more desirable properties, and introducing self-healing properties could be one of the options for further optimization in the future.

Characterization and treatment effects on Mutaka kaolin for additive in coatings: Mineral composition, thermal and structural modifications

Previous studies in Uganda have primarily explored kaolin's applications in composites, pottery, bricks, and insulation, neglecting its potential for coatings and paints, which is crucial for industrialization and saving foreign exchange. This study investigates the transformation of kaolin through various treatments and analyzes their impacts on its physical and chemical properties for potential use in coating applications. Thermal analysis, X-ray Fluorescence Spectroscopy (XRF), X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS), and transmission electron microscopy (TEM) techniques were employed to assess these alterations. The results show that thermal treatment of kaolin at 45.9 °C had minimal impact on mass loss, while the crystallinity of kaolinite was found to be lost around 600 °C, resulting in structural changes. XRF result demonstrates variations in SiO2 and Al2O3 composition, with low TiO2 content desirable for paint and coating applications. XRD results showed well-defined diffractions associated with kaolinite in all treated and untreated kaolin samples. The presence of K-feldspar and quartz are also identified. However, the thermal treatment at 800 °C transforms kaolinite into metakaolin, essential for enhancing coating properties. SEM-EDS results indicate increased porosity and reduced impurities in the thermal-treated sample, which might enhance the whiteness and suitability of pigment and binder dispersion in coatings. TEM images confirmed the hexagonal nature of kaolinite platelets and demonstrated the amorphous nature of kaolin nanoparticles with ammonium molybdate treatment, which led to the delamination and exfoliation of kaolinite layers, improving dispersibility. Kaolin thermally treated exhibited good crystallinity, solid growth, cubic morphology, and uniform size distribution. These findings suggest that tailored treatments can optimize kaolin's properties, making it a promising additive for high-performance coatings.

Nanoceramic-based coatings for corrosion protection: a review on synthesis, mechanisms, and applications

Corrosion is a pervasive issue with significant economic and safety implications across various industries. Nanoceramic-based coatings have emerged as a promising solution for corrosion protection due to their unique properties and mechanisms. This review aims to comprehensively examine the synthesis, mechanisms, and applications of nanoceramic-based coatings for corrosion protection. The review begins by highlighting the importance of corrosion protection and its impact on different industries. It introduces nanoceramic-based coatings as a potential solution to address this challenge. The objective is to provide a thorough understanding of the synthesis methods, mechanisms, and applications of these coatings. The fundamental principles of corrosion and different corrosion mechanisms are discussed, along with the limitations of traditional corrosion protection methods. The review emphasizes how nanoceramic-based coatings can overcome these limitations and provide superior corrosion resistance. Various synthesis methods, including sol-gel, electrodeposition, and physical vapor deposition, are described in detail, along with the factors influencing the synthesis process. Recent advancements and innovations in nanoceramic coating synthesis techniques are also highlighted. This looks at how coatings made with tiny ceramic particles protect against corrosion. It examines the importance of small-scale details like particle size, shape, and what the particles are made of. The formation of passive layers, self-healing mechanisms, and barrier properties of nanoceramic coatings are explained. The diverse applications of nanoceramic coatings for corrosion protection in industries such as automotive, aerospace, and marine are comprehensively discussed. Case studies and examples demonstrating the significant corrosion resistance and improved performance achieved with nanoceramic coatings are presented.

Powder and High-Solid Coatings

This Special Issue presents a series of research papers and reviews about the actual trend of powder and high solid coatings which show the advantage of great environmental sustainability by avoiding the massive use of organic solvents. Moreover, some very interesting studies exist on the move from a simple protective layer to a smart coating with additional properties, both for the aesthetic and functional aspects.

Accelerated Corrosion Tests in Quality Labels for Powder Coatings on Galvanized Steel-Comparison of Requirements and Experimental Evaluation

Powder coatings are widely applied for corrosion protection of steel, aluminum, and hot dip galvanized steel in a variety of corrosive environments. Powder coatings are subjected to a number of strict laboratory tests to determine their mechanical properties, corrosion resistance, and color stability. Among European quality certificates for powder coatings applied to galvanized steel, the most commonly recognized are GSB-ST and Qualisteelcoat certificates, which also refer to the EN 13438 standard. Certificates of quality for powder coatings are constantly updated according to the latest research results and experience of specialists operating in the field of corrosion protection. This paper presents an experimental evaluation of how the required length of selected accelerated corrosion tests can affect the final assessment of powder coatings. On the example of two powder painting systems: polyester as well as based on epoxy and polyester resins, the paper presents the influence of the time of accelerated corrosion tests: ISO 6270, ISO 9227 (Neutral Salt Spray and Acetic Acid Salt Spray), and ISO 3231 on the protective properties of the coatings. The results of damage assessment according to ISO 4628 have been correlated with the requirements of particular quality specifications. Additionally, based on FTIR (Fourier Transform Infrared Spectroscopy) and EIS (Electrochemical Impedance Spectroscopy) analyses, the influence of the applied corrosion tests on the degradation degree of the coatings studied has been presented. The paper aims to present a tests for those powder coating systems applied to facilities for which the main requirement is corrosion resistance rather than aesthetics.