Development and Research of Anti-Corrosion Polymer Coatings with Microdefect Blocking Effect

Corrosion of materials is a global issue affecting various industries. It leads to a gradual decline in the durability and reliability of materials, resulting in significant economic losses and posing serious risks to human health. To address the challenge of enhancing reliability and durability when materials are exposed to aggressive environments, this study developed new polymer protective coatings. These coatings involve reinforcing an epoxy resin-based polymer matrix with zinc and microencapsulated corrosion inhibitors (activated Al₂O₃ + HEDP; activated Al₂O₃ + PPA; activated Al₂O₃ + ATMP). These microscopic containers encapsulate the corrosion inhibitors. The microstructure of the microcapsules was examined using scanning electron microscopy (SEM) and optical microscopy. Accelerated corrosion tests were performed on the reinforced modified coatings. Coatings reinforced with activated Al₂O₃ + HEDP microcapsules demonstrated excellent corrosion resistance in a 3% NaCl solution. In contrast, samples coated with unmodified zinc-filled coatings and coatings modified with Al₂O₃ + PPA exhibited the lowest resistance in a 3% NaCl solution. The study also investigated the microdefect-blocking effect in reinforced coatings, which is achieved by filling the pores of the polymer coating with products formed from inhibitor-metal interactions.