Anticorrosion Coating with Heterogeneous Assembly of Nanofillers Modulated by a Magnetic Field

An anticorrosive coating with randomly distributed passive barriers and regionally enriched active corrosion inhibitors is developed by integrating mica nanosheets (MNSs) and magnetic-responsive core-shell mesoporous nanoparticles with 2-mercaptobenzothiazole (Fe₃O₄@mSiO₂/MBT) under magnetic field incubation. The bottom enriched Fe₃O₄@mSiO₂/MBT rapidly releases the MBT to form a passivation layer on corrosion sites, enhancing the corrosion inhibition efficiency by 30.36% compared with the control (NP_0.7EP-R). The impedance modulus |Z|_0.01 Hz of the sample (NP_0.7/MNS_0.5/EP) increases by five orders of magnitude compared with that of its control (NP_0.7/MNS₀EP) after 30 days of corrosion immersion. NP_0.7/MNS_0.5/EP exhibited the lowest corrosion rate (3.984 × 10^-5 mm/year) as compared to the other samples. Notably, the coating in a fractured state still maintains superior corrosion inhibition even after 40 day salt spray testing. The differentiated distribution of nanofillers was well confirmed by optical microscopy and SEM-EDS, and the synergistic effect of the active/passive integrated anticorrosive coating with merits of both comprehensive protection and fast responsiveness was systematically explored.