Synthesis and Characterization of Epoxy-Rich TMOs Deposited on Stainless Steel for Corrosion Applications

Atzin Ferrel-Alvarez,Subramaniam Velumani,Ganesh Regmi,Homero Castaneda,Brenda B Galicia,Adhikari Ashok

doi:10.3390/coatings12030387

Abstract

Epoxy-trimetallic oxide (epoxy-TMO) coatings of ZrO2:TiO2:ZnO at different compositions were synthesized and used to protect a stainless steel surface. The different TMO compositions were synthesized using the ball-milling method and later dispersed on the polymer matrix. The different characterizations performed on these coatings showed that the epoxy-TMO coating with a ratio of 50:40:10 (wt%) exhibited the highest corrosion resistance, in the order of ~1012 Ωcm2, due to the barrier effect of the distributed particles after 28 days in an aggressive environment (3.5 wt% NaCl solution). The influence of the metal oxides in forming a semiconductor layer produces a capacitor-like behavior, influencing corrosion control via a mass transfer mechanism barrier. The water uptake reveals the effect of each metal oxide in the formation of a physical barrier due to the dispersion mechanism, as well as how the particles function within the polymer matrix.

Highlights

Stainless steel (SS) is widely used in industry due to its excellent corrosion resistance and low cost
This study proposes a novel and hybrid combination of ZrO2, TiO2, and zinc oxide (ZnO) nanoparticles at different ZrO2 -richness ratios using the ball-milling technique, and added to a commercial epoxy resin intended to achieve anticorrosive properties
We present a systematic fundamental analysis of the different nanoparticles’ ratios in the epoxy matrix, with a minimum wt%, in order to determine the efficacy in the corrosion protection properties on SS substrates

Summary

Introduction

Stainless steel (SS) is widely used in industry due to its excellent corrosion resistance and low cost. Organic coatings are the most widely applied method for corrosion protection of metallic materials, providing a protective barrier and preventing the diffusion of oxygen and water through the insulating layer [2]. Epoxy resins are the most used polymers in the protection of steel, due to their excellent physical and chemical properties—such as adhesion, chemical resistivity, and mechanical and dielectric properties [3]—and they are widely used for industrial applications such as aerospace parts, electrical laminates, and construction materials [4]. The extensive work was applied on a previously reported highly resistive TMO coating synthesized via the ball-milling method. This synthesis method uses mechanical energy to activate chemical reactions and structural changes, and is able to reduce the particle size [11].

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