Optimizing Anticorrosion Coating Performance: Synthesis of Polyurethane/Epoxy Hybrids.

Area of Science:

• Materials Science
• Polymer Chemistry
• Corrosion Engineering

Background:

• Conventional coatings often fail to meet mechanical and chemical durability requirements.
• Metal structures require robust corrosion-resistant coatings for longevity.

Purpose of the Study:

• To develop and evaluate polyurethane/epoxy hybrid coatings (PUAE) with enhanced performance.
• To investigate the effect of varying epoxy resin content on coating properties.

Main Methods:

• Synthesized PUAE coatings with 5%, 10%, and 15% epoxy content.
• Characterized mechanical properties (tensile strength, adhesion, hardness, elongation).
• Assessed thermal stability (TGA), viscosity, contact angle, and chemical resistance.

Main Results:

• Increased epoxy content improved tensile strength (up to 86.3 MPa) and adhesion (up to 8.3 MPa).
• Hardness increased (to 98 Shore A), while elongation decreased (to 95%), indicating enhanced stiffness.
• Thermal stability improved (390 °C max decomposition), hydrophobicity increased (149° contact angle), and solvent/acid resistance was superior.

Conclusions:

• Epoxy content critically influences the structural, mechanical, and anticorrosive properties of PUAE coatings.
• PUAE15 demonstrates significant potential as an advanced anticorrosive coating material.
• The developed hybrid coatings offer a viable solution for extending the lifespan of metal structures.