Cavitation pit evolution process of epoxy and polyurea coatings on mortar substrates

This study focuses on unraveling the failure mechanisms of three distinct polymer-coating structures applied to mortar substrates: an epoxy coating (MEP1), an epoxy coating with an intermediate epoxy mortar layer (MEP2), and a polyurea coating with an intermediate epoxy mortar layer (MPU). Ultrasonic cavitation experiments are conducted to investigate the initial stages of cavitation erosion. The damaged surfaces of these three coating structures are meticulously investigated and characterized. An in-depth analysis is performed on the distribution characteristics of cavitation pits and the evolutionary patterns of these pits. The results indicate that the introduction of epoxy mortar as an intermediate layer significantly enhances the material's cavitation resistance by improving its energy absorption capacity. This enhancement delays the formation of cavitation pits on the coating surface. Additionally, the superior adhesive properties of the intermediate epoxy mortar with the mortar substrate prevent direct cavitation erosion from forming on the substrate, even when brittleness failure occurs and coating erosion is observed on the surface epoxy polymer. The polyurea coatings demonstrate exceptional elastic-plastic deformation capabilities. When combined with the intermediate epoxy mortar layer, MPU can withstand prolonged and repetitive cavitation impacts, resulting in minimal coating erosion.

Anticorrosion performance assessment of silane-modified chitosan/epoxy primer coatings on mild steel in saline environment using computational simulation techniques

The anticorrosion performance of silane-modified chitosan/epoxy primer coatings was evaluated using quantum chemical computations (QCC) and molecular dynamics simulation (MDS) techniques. The objective was to appraise the molecular/atomistic level performance of silane-modified chitosan/epoxy primer coating system on mild steel in saline water to be able to design robust anticorrosion epoxy nanocomposite primer coating for marine application. The QCC showed that quantum parameters for (3-aminopropyl) trimethoxy silane-modified chitosan nanocluster (AMCN) are optimum and therefore correspond to high corrosion protective capability. The adsorption energies (E_ads) for AMCN/epoxy, tetraethoxysilane-modified chitosan/epoxy, chitosan-modified epoxy, and unmodified epoxy coatings were found to be - 3094.65, - 2,630.00, - 2,305.77, and - 1,189.33 kcal/mol, respectively. The high negative value of E_ads indicates the coating molecules interacted and adsorbed strongly on the mild steel surface. Hence, AMCN/epoxy coating is potentially most corrosion-resistant than the others. Further, it is established that shorter bond length corresponds to higher bond strength and therefore indicates chemical interaction. Thus, the radial distribution function showed the bond lengths between atoms of the AMCN and mild steel surfaces were shorter than those of other molecules. Overall, AMCN/epoxy coating molecules possess good anticorrosion properties and therefore would perform well if deployed for service in saline environments.

A novel epoxy coating with nanocatalytic anticorrosion performance achieved by single-atom Fe-N-C catalyst

In view of the critical importance of oxygen to corrosion evolution, to starve corrosion via depleting oxygen in coatings is a promising strategy. In this work, a novel nanocatalytic anticorrosion concept is proposed to design new coating with outstanding corrosion resistance. Different from the passive barrier of traditional coatings and self-repair after corrosion of current stimuli-feedback coatings, such coating could spontaneously eliminate internal diffused oxygen and greatly suppress the corrosion process. As a proof of concept, single-atom Fe-N-C electrocatalyst with isolated FeN₄ active sites is synthesized by a simple confined carbonization method, exhibiting excellent oxygen reduction performance (E_1/2 = 0.902 V). In composite coating, the evenly dispersed Fe-N-C compensates for the coating defects and serves as oxygen scavengers, which could actively adsorb and consume ambient oxygen, thereby preventing oxygen penetration to the metal substrate surface, eliminating the oxygen contribution to corrosion and significantly boosting the anticorrosion performance of epoxy coating. This in-situ mediation for oxygen in coating prevents metal substrate from receiving new supply of oxygen, while imparting active anticorrosion property to the coating.

Development of silica-coated rare-earth doped strontium aluminate toward superhydrophobic, anti-corrosive and long-persistent photoluminescent epoxy coating

Long-persistent phosphorescent smart paints have the ability to continue glowing in the dark for a prolonged time period to function as energy-saving products. Herein, new epoxy/silica nanocomposite paints were prepared with different concentrations of lanthanide-doped aluminate nanoparticles (LAN; SrAl₂ O₄ : Eu²⁺ , Dy³⁺ ). The LAN pigment was firstly coated with SiO₂ utilizing the heterogeneous precipitation technique to provide LAN-encapsulated between SiO₂ nanoparticles (LAN@SiO₂ ). The epoxy/silica/lanthanide-doped aluminate nanoparticles (ESLAN) nanocomposite paints were coated on steel. The prepared ESLAN paints were studied by transmission electron microscope (TEM), infrared spectra (FTIR), scanning electron microscope (SEM), X-ray fluorescence analysis (XRF), and energy-dispersive X-ray spectra (EDS). The transparency and coloration properties of the nanocomposite coated films were explored by CIE Lab parameters and photoluminescence spectra. The ultraviolet-induced luminescence properties of the transparent coated films demonstrated greenish phosphorescence at 518 nm upon excitation at 368 nm. Both hardness and hydrophobic activities were investigated. The anticorrosion activity of the nanocomposite films coated onto mild steel substrates immersed in NaCl_(aq) (3.5%) was studied by the electrochemical impedance spectral (EIS) analysis. The silica-containing coatings were monitored to exhibit anticorrosion properties. Additionally, the nanocomposite films with LAN@SiO₂ (25%) exhibited the optimized long-lasting luminescence properties in the dark for 90 minutes. The nanocomposite films showed highly reversible and durable long-lived phosphorescence.

Interfacial assembled mesoporous polydopamine nanoparticles reduced graphene oxide for high performance of waterborne epoxy-based anticorrosive coatings

Embedding two-dimension micro/nanocontainers containing corrosion inhibitors into organic coating is a well-established concept to impart the coating with enhanced barrier and self-healing feature. Herein, a versatile nanoemulsion assembly approach was used to synthesis nanocarriers combing mesoporous polydopamine nanoparticles (MPDA) with reduced graphene oxide (GO), which was employed to encapsulate corrosion inhibitors (benzotriazole, BTA) to improve the anticorrosion performance of waterborne epoxy coating. The BTA release profiles from synthesized GO with MPDA (PDAG) demonstrated the rapid pH-triggered activities to acidic corrosion environment. With the addition of BTA-loaded PDAG, the composited epoxy coatings presented self-repairing behavior and enhanced corrosion resistance during long-term immersion. The outstanding anticorrosion performance is attributed to dual-protection mechanism provided by BTA-loaded PDAG: (1) MPDA endows GO with satisfactory interface compatibilities and thus provides impermeable barrier to delay the penetration process of corrosive electrolyte; (2) corrosion inhibitors including BTA and polydopamine form the adsorption layers on bare steel surface to resist continuous corrosion at metal/coating interface.

Synthesis of graphene oxide nanosheets decorated by nanoporous zeolite-imidazole (ZIF-67) based metal-organic framework with controlled-release corrosion inhibitor performance: Experimental and detailed DFT-D theoretical explorations

For the first time, the zeolite-imidazole (ZIF-67) framework, a new subfamily of metal-organic frameworks (MOFs), is synthesized on the graphene oxide (GO) platform. Co²⁺ (as a central atom) and 2-methylimidazole (as organic ligands) were assembled to fabricate ZIF-67/GO NPs for providing epoxy-based anti-corrosion coatings with both active (self-healing) and passive (barrier) performance. Also, the ZIF-67/GO NPs were modified by 3-Aminopropyl triethoxysilane (APS) to improve the particles compatibility with the epoxy matrix and control their solubility in saline media. The FE-SEM, FT-IR, UV-Vis, Raman, TGA, and low-angle XRD techniques were used to prove the successful ZIF-67 particles growth onto the GO platforms. Tafel (potentiodynamic) polarization test demonstrated that the ZIF-67/GO@APS NPs could protect the surface of steel through mixed anodic/cathodic type (O₂ reduction/Fe oxidation) mechanisms and the corrosion current density of the iron sample decreased to 1.41 µA·cm^-2. Interestingly, the epoxy coatings containing ZIF-67/GO and ZIF-67/GO@APS particles revealed long-term corrosion protection durability and outstanding self-healing anti-corrosion performance, which were well studied via EIS, salt spray, cathodic delamination, and pull-off techniques. The impedance value at the lowest frequency for the coating containing ZIF-67/GO@APS after 50 days decreased from 10.7 Ω·cm² to 10.2 Ω·cm² that showed the lowest reduction among the studied samples.