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Unraveling the enhanced interfacial adhesion of epoxy coatings on cerium conversion-coated metals: a multiscale investigation by thermodynamic and molecular dynamics

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Purpose The interfacial performance of epoxy coatings strongly influences their long-term corrosion protection on metallic substrates. This study aims to elucidate how cerium-based conversion coatings affect epoxy/metal interfacial interactions and adhesion mechanisms. Design/methodology/approach Electrochemical impedance spectroscopy (EIS) and pull-off tests were used to assess interfacial stability and adhesion on differently pretreated substrates. A surface-energy-based thermodynamic model was implemented to predict interfacial bonding strength. In addition, density functional theory (DFT) calculations and molecular dynamics (MD) simulations were conducted to probe atomic-scale interactions and dynamic adsorption behavior at the epoxy/CeO2 interface. Findings Cerium conversion coated substrates exhibited superior interfacial stability and adhesion compared to other pretreatments, as indicated by higher impedance values and cohesive failure within the coating. Thermodynamic predictions of interfacial bonding strength were consistent with EIS and adhesion results. DFT results revealed enhanced electronic interactions and charge transfer at the epoxy/CeO2 interface, while MD simulations demonstrated stable adsorption and resistance to interfacial disruption under realistic conditions. Originality/value This work integrates experimental electrochemical and adhesion characterization with thermodynamic and atomistic simulations to provide a predictive understanding of corrosion-resistant coating interfaces, offering a rational basis for interface design beyond conventional trial-and-error approaches.

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This study examines the inhibitory effect of Pelargonium Hortorum Essential Oil (PHEO) as green inhibitor for mild steel (MS) corrosion in 1 M HCl electrolyte, which is a novel application compared to previous studies that focused on its aromatic and medicinal properties. This study was carried out using different electrochemical techniques (electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP)) and scanning electronic microscopy (SEM) analysis. The PDP results indicated that PHEO compound react as an effective anticorrosion product confirmed by the creation of a defensive adsorbed layer on the MS area founded by SEM analysis. In addition, PDP findings indicated that the PHEO behaves as a mixed-type inhibitor. Furthermore, it is founded that the inhibition efficiency (η%) upsurges with the PHEO contents, reaching approximately 96.55% at 800 ppm PHEO, which is a notable achievement compared to other essential oils studied as corrosion inhibitors. The temperature effect study revealed that PHEO maintains significantly its inhibitory activity even at elevated temperatures, which is an important aspect to consider for practical applications. The study combines experimental results with Density functional theory (DFT) calculations and Molecular Dynamics (MD) simulations to identify the responsible sites for adsorption and explain the action mode of the major components of PHEO. These studies confirmed the experimental results and explain the action modes of the major compounds of PHEO on MS surface.

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