Abstract
Mixed ZrO2 and Cr2O3 nanoparticles (NPs) were prepared using a liquid phase chemical technique and applied as reinforced filler for epoxy coatings with different weight ratios ranged from 0.5 to 2.5 wt.% to protect carbon steel from corrosion. The ZrO2/Cr2O3 NPs were used to catalyze the curing of the epoxy composite films to modify their mechanical and thermal characteristics on the steel surface. The crystalline structure, particle sizes, and surface morphologies of the prepared ZrO2 and Cr2O3 NPs were characterized to investigate their chemical composition and dispersion. The thermal stability of epoxy ZrO2/Cr2O3 coating films was investigated by thermogravimetric analysis (TGA), and the mechanical properties of the cured epoxy films were also studied. The dispersion of the Cr2O3/ZrO2 NPs into the epoxy matrix was investigated by scanning electron microscope (SEM), dynamic mechanical analysis (DMA) and TGA analyses. The results of salt spray test, used to investigate the anticorrosion performance of the epoxy coatings) were combined with thermal characteristics to confirm that the addition of Cr2O3/ZrO2 NPs significantly improved the corrosion resistance and the thermal stability of epoxy coating. The mechanical properties, adhesion, hardness, impact strength, flexibility and abrasion resistance were also improved with the addition of ZrO2/Cr2O3 NPs filler content.
Highlights
Epoxy resins have interesting mechanical and barrier properties to protect several substrates from corrosion in aggressive environment beside they have interesting adhesive properties due to their high modulus, high failure strength, and low creep mechanical characteristics [1,2,3]
The formation of micro-cracks and holes due to fast curing of heterogeneous epoxy networks facilitates the penetration of corrosive electrolytes containing oxygen, water, and ions from coat to substrate surface when epoxy coatings exposed against aggressive environmental to a long time [2]
The crystalline lattice structure of ZrO2 and Cr2 O3 NPs was confirmed from X-ray diffraction (XRD) data represented in Figure 1a,b, respectively
Summary
Epoxy resins have interesting mechanical and barrier properties to protect several substrates from corrosion in aggressive environment beside they have interesting adhesive properties due to their high modulus, high failure strength, and low creep mechanical characteristics [1,2,3]. The epoxy coating performances were based on their good adhesion and physical barrier between epoxy and the substrate surface against several corrosive environments [2,3]. The formation of micro-cracks and holes due to fast curing of heterogeneous epoxy networks facilitates the penetration of corrosive electrolytes containing oxygen, water, and ions from coat to substrate surface when epoxy coatings exposed against aggressive environmental to a long time [2]. The penetration of the corrosive ions into the primer epoxy coatings reduces the adhesion of cured epoxy with substrate surfaces [2,3]. It is reported that the chemical treatment of the surface substrate beside reinforcement of the epoxy with nano-fillers can improve the adhesion of epoxy primers with
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