AbstractIn this study, the interfacial interaction between the 3‐aminopropyltriethoxysilane (APTES) modified basalt fibers (BF@Ax) and waterborne epoxy was studied by using thermodynamic approaches and creating a “wetting‐reagglomeration‐adsorption” isocontour map of waterborne epoxy. Combined with the TG‐DSC, dynamic thermomechanical analysis (DMA), tensile, flexural, electrochemical impedance spectrum (EIS) and salt spray tests, the enhancement effects of interfacial interaction on thermal stability, mechanical properties and corrosion resistance were demonstrated. From the isocontour map, APTES modification reduces the surface energies of BF@Ax fillers from 53.05 to 50.27 mJ/m2, which results in the driving energy for reagglomeration decreasing from 17.04 to 10.41 mJ/m2 and the adsorption energy increasing from 20.24 to 20.77 mJ/m2, suggesting that the BF fillers' dispersion performance and interfacial strengths of BF composite coatings are enhanced. Compared to the varnish coating, the tensile and flexural strengths of the epoxy (EP)/BF@A9.5 coating are increased by 55.87% and 36.36%, respectively, and the thermal stability is enhanced, due to the BF@A9.5 fillers' optimal dispersion. Meanwhile, EP/BF@A5.0 coating has the best corrosion resistance with |Z|0.01Hz value above 109 Ω cm2 after 35 days and salt spray resistance exceeding 120 days. This work provides a new insight into how the interfacial interaction between the one‐dimensional rod fillers and matrices affects the composites' properties from the thermodynamics.Highlights Waterborne epoxy coatings were reinforced by the modified chopped BFs. Impact of APTES modification on the BF surface energy was uncovered. Interaction of BFs/epoxy interfaces was studied by thermodynamic approaches. Effect of interfacial interaction on properties of coatings was unveiled.
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