Sol–gel incorporation of silica nanofillers for tuning the anti-corrosion protection of acrylate-based coatings

Abstract

The aim of the present work is to synthesize through sol–gel approach new hybrid polymeric nanocomposites to be used as coating materials. An acrylic-based polymer was prepared by free-radical copolymerization of two monomers widely used for coatings, namely 2-ethylhexylacrylate (EHA) and glycidyl methacrylate (GMA) bearing epoxy moieties, in which silica nanoparticles were incorporated by in situ acid hydrolysis and subsequent condensation of tetraethoxysilane (TEOS). Glycidoxypropyl trimethoxysilane (GPTS) was used as coupling agent to fine-tune the compatibility between organic and inorganic phases. The morphology, mechanical properties and corrosion resistance of thin films applied on aluminum alloys were optimized by varying the content of silica nanoparticles whose properties were strongly affected by the TEOS/GPTS ratios. Performances of the obtained hybrid materials were scrutinized by atomic force microscopy (AFM), differential scanning calorimetry (DSC), thermal gravimetric analysis (TGA), and electrochemical impedance spectroscopy (EIS). Thus it was evidenced that an optimum amount of silica nanoparticles with a precise morphology and composition in term of TEOS/GPTS ratio is needed to maintain good coating barrier properties. Outstanding anti-corrosion protection was reached by using optimized hybrid films.