Zn–Al with NO2− as a corrosion inhibitor epoxy-coated carbon steel under artificial atmospheric conditions

Abstract

This study evaluated Zn–Al–NO2− layered double hydroxide as a corrosion inhibitor in a high-thickness epoxy resin coating (200 µm). The layered double hydroxide was tested in a NaCl solution, using electrochemical impedance spectroscopy. The formed oxides were analysed by X-ray diffraction and energy dispersive X-ray spectroscopy. The corrosion resistance of the epoxy coating (with and without layered double hydroxide) was analysed by electrochemical impedance spectroscopy after exposure to a NaCl solution, salt spray, or a weather-O-meter chamber in a simulated atmospheric environment. The electrochemical impedance spectroscopy measurements for the free layered double hydroxide in a NaCl solution revealed that layered double hydroxide prompted the formation of a compact, protective, and insoluble oxide layer on the carbon steel surface. The Cl− permeability through the epoxy resin film was 5.88 times lower for the film containing layered double hydroxide than for the control. The layered double hydroxide was added to the epoxy coating at a 5 wt-% to evaluate the behaviour of the coating in aggressive environments. The entry of aggressive ions was controlled by the ability of the layered double hydroxide to capture them and release the corrosion inhibitors. Thus, the layered double hydroxide worked as a trap for these aggressive ions and enhanced the performance of the coating. Therefore, a layered double hydroxide addition could benefit a high-thickness coating exposed to an aggressive environment and UV radiation.